2004-2005 YAMAHA 115HP 2-STROKE OUTBOARD by www.heydownloads.com

F115C LF115C

SERVICE MANUAL *LIT186160271* LIT-18616-02-71

68V-28197-1F-11

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

F115C, LF115C SERVICE MANUAL ÂŠ2003 by Yamaha Motor Corporation, USA 1st Edition, October 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-71

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. For instance, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol. â&#x20AC;˘ Bearings Pitting/scratches â&#x2020;&#x2019; Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.

MODEL INDICATION Multiple models are mentioned in this manual and their model indications are noted as follows. Model name

F115AET

FL115AET

USA and Canada name

F115TR

LF115TR

Indication

F115AET

FL115AET

ILLUSTRATIONS The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page. 4 It is important to refer to the job instruction charts at the same time as the exploded views. These charts list the sequence that the procedures should be carried out in, as well as providing explanations on part names, quantities, dimensions and important points relating to each relevant task. Example: O-ring size

39.5 × 2.5 mm: inside diameter (D) × ring diameter (d) D

5 In addition to tightening torques, the dimensions of the bolts and screws are also mentioned. Example: Bolt and screw size

10 × 25 mm

: bolt and screw diameter (D) × length (L) D L

6 In addition to the exploded views and job instruction charts, this manual provides individual illustrations when further explanations are required to explain the relevant procedure.

E 1

SYMBOLS

GEN INFO

Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.

SPEC

1 2 3 4 5 6 7 8 9

INSP ADJ

FUEL

LOWR

POWR 7

General information Specifications Periodic inspections and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Trouble analysis

BRKT

–

ELEC

Symbols 0 to E indicate specific data.

0 A B C D E

TRBL ANLS A

Special tool Specified liquid Specified engine speed Specified torque Specified measurement Specified electrical value [Resistance (Ω), Voltage (V), Electric current (A)]

Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of the lubrication point.

E G

H M

L LT

271

242

N LT

572

SS LT

F Apply Yamaha 4-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide oil

Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point. I Apply Gasket Maker® J Apply Yamabond #4 (Yamaha bond number 4) K Apply LOCTITE® No. 271 (Red LOCTITE) L Apply LOCTITE® No. 242 (Blue LOCTITE) M Apply LOCTITE® No. 572 N Apply silicon sealant

CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT

GEN INFO

SPEC

INSP ADJ

FUEL

POWR

LOWR

BRKT â&#x20AC;&#x201C;

ELECTRICAL SYSTEMS TROUBLE ANALYSIS

ELEC

TRBL ANLS

1 2 3 4 5 6 7 8 9

GEN INFO

CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION.................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-5 REMOVING AND INSTALLING ............................................................... 1-7

1 2 3 4 5 6 7 8 9

GEN INFO

IDENTIFICATION

SERIAL NUMBER The outboard motor serial number is stamped on a label attached to the port clamp bracket.

S68V1010

1 2 3 4

Model name Approved model code Transom height Serial number

1020

STARTING SERIAL NUMBERS The starting serial number blocks are as follows:

1-1

Model name

Approved model code

F115TR

68V

LF115TR

68W

Starting serial number L: 1016859 X: 1016859 X: 1000743 -

GEN INFO

SAFETY WHILE WORKING SAFETY WHILE WORKING

E 1

The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.

1030

VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.

1040

SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. 1050

OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

1060

1-2

GEN INFO

SAFETY WHILE WORKING

Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wipingrag in your pocket. 4. Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working, is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes.

GOOD WORKING PRACTICES 1. The right tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner â&#x20AC;&#x201C; do not improvise. 2. Tightening torque Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.

1070

1-3

GEN INFO

SAFETY WHILE WORKING

3. Non-reusable items Always use new gaskets, packings, Orings, split-pins, circlips, etc., on reassembly.

1080

DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly.

1090

3. After assembly, check that moving parts operate normally.

1100

4. Install bearings with the manufacturerâ&#x20AC;&#x2122;s markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter.

1-4

GEN INFO

SPECIAL TOOLS

Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment.

NOTE: • For U.S.A. and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YU-” or “YW-”. • For others countries, use part numbers that start with “90890-”.

MEASURING

1 Pressure tester P/N. YB-35956 90890-06762 2 Mity vac P/N. YB-35956 90890-06756 3 Pinion height gauge P/N. YB-34432-6, YB-34432-11, YB-34432-97 90890-06702 4 Dial gauge set P/N. YU-03097 90890-01252 5 Magnetic base P/N. YU-34481 90890-06705 6 Digital caliper P/N. 90890-06704 7 Backlash indicator P/N. YB-06265 90890-06706 8 Magnetic base attaching plate P/N. YB-07003 90890-07003 9 Fuel pressure gauge P/N. YB-06766 90890-06786 0 Hydraulic pressure gauge P/N. 90890-06776

1-5

GEN INFO A

SPECIAL TOOLS

E A Up-relief valve attachment P/N. 90890-06773 Down-relief valve attachment P/N. 90890-06774 B Digital tester P/N. J-39299 90890-06752 C Peak voltage adapter P/N. YU-39991 ................................ 90890-03169 ........................... D Spark gap tester P/N. YM-34487 ............................... 90890-06754 ........................... E Shimming gauge P/N. YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7 F Shimming gauge P/N. YB-34468-2 G Shimming plate P/N. 90890-06701 H Shift rod wrench P/N. YB-06052 90890-06052 I Test harness P/N. 90890-06790, 90890-06791, 90890-06792, 90890-06793

1-6

a b a b

GEN INFO

SPECIAL TOOLS

REMOVING AND INSTALLING 1

1 Flywheel magnet assembly holder P/N. YB-06139 ................................ a 90890-06522 ........................... b 2 Universal puller P/N. YB-06117 ................................ a 90890-06521 ........................... b 3 Bearing/oil seal attachment P/N. YB-06196 ................................ a 90890-06653 ........................... b 4 Driver rod P/N. YB-06071 90890-06602, 90890-06604, 90890-06605, 90890-06606, 90890-06652 5 Bearing/oil seal attachment P/N. YB-06377 90890-06630 6 Bearing/oil seal attachment P/N. YB-06199 90890-06620 7 Piston ring compressor P/N. YU-33294 ................................ a 90890-06530 ........................... b 8 Bearing separator P/N. YB-06219 ................................ a 90890-06534 ........................... b 9 Guide plate stand P/N. 90890-06538 0 Guide plate P/N. 90890-06501

1-7

GEN INFO

SPECIAL TOOLS

E A Bearing puller P/N. 90890-06535 B Bearing/oil seal attachment P/N. 90890-06661, 90890-06640 C Ring nut wrench P/N. YB-34447, YB-06578 90890-06511, 90890-06578 D Ring nut wrench extension P/N. 90890-06513 E Propeller shaft housing puller P/N. YB-06207 ................................ 90890-06502 ........................... F Center bolt P/N. 90890-06504 G Slide hammer P/N. YB-06096 90890-06531 H Small universal claws P/N. 90890-06536 I Bearing/oil seal depth plate P/N. YB-06213, YB-34474 .............. 90890-06603 ........................... J Drive shaft holder P/N. YB-06151 90890-06519 K Pinion nut holder P/N. 90890-06505 L Pinion nut holder attachment P/N. 90890-06507 M Bearing/oil seal attachment P/N. YB-06194, YB-06195, YB-06200, YB-06376 90890-06607, 90890-06610, 90890-06612, 90890-06633, 90890-06636 N Bearing puller P/N. 90890-06523 O Large universal claws P/N. 90890-06532

1-8

a b

GEN INFO

SPECIAL TOOLS

E P Slide hammer attachment P/N. YB-06335 90890-06514 Q Oil filter wrench P/N. YU-38411 90890-01426 R End screw wrench P/N. YB-06175-1A S End screw wrench P/N. YB-06548 90890-06548 T Valve spring compressor P/N. YM-01253 90890-04019 U Valve spring compressor adapter (ø22 mm) P/N. YB-06554 90890-06554 V Valve seat cutter set P/N. YM-91043-C............................ a 90890-06803 ........................... b W Valve seat cutter holder (ø6 mm) P/N. YB-06553 90890-06553 X Valve seat cutter P/N. YB-06555 (45˚ - 30 mm) YB-06556 (90˚ - 30 mm) 90890-06555 (45˚ - 30 mm) 90890-06556 (90˚ - 30 mm) Y Valve guide remover (ø5.9 mm) P/N. YM-4064-A 90890-04064 Z Valve guide reamer (ø6 mm) P/N. YM-04066 90890-04066 [ Crankshaft holder P/N. YB-06552 90890-06552

[

1-9

GEN INFO \

SPECIAL TOOLS

E \ Bearing installer P/N. YB-41446 ] Bearing cup installer P/N. YB-06167 _ Roller bearing installer/remover P/N. YB-06432-1A

]

1-10

SPEC

CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS.......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-3 POWER UNIT............................................................................................ 2-3 LOWER UNIT............................................................................................ 2-7 ELECTRICAL ............................................................................................. 2-7 DIMENSIONS ......................................................................................... 2-10 TIGHTENING TORQUES .............................................................................. 2-13 SPECIFIED TORQUES ............................................................................ 2-13 GENERAL TORQUES ............................................................................. 2-15

1 2 3 4 5 6 7 8 9

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS Item DIMENSION Overall length Overall width Overall height (L) (X) Boat transom height (L) (X) WEIGHT (without propeller) (L) (X) PERFORMANCE Maximum output Full throttle operating range Maximum fuel consumption POWER UNIT Type Number of cylinders Displacement Bore × stroke Compression ratio Minimum compression pressure(*1) Fuel system Fuel injection system Starting system Ignition control system Alternator output Spark plugs (NGK) Cooling system Exhaust system Lubrication system (*1)

Model

Unit

F115TR

LF115TR

mm (in) mm (in)

825 (32.5) 498 (19.6)

mm (in) mm (in)

1,609 (63.3)

mm (in) mm (in)

508 (20.0)

kg (lb) kg (lb)

183 (403)

— 1,736 (68.3) — 635 (25.0)

— 188 (414)

kW (hp) @ 5,500 r/min

84.6 (115)

r/min

5,000 - 6,000 38 (10.0, 8.4)

L (US gal, lmp gal)/hr @ 6,000 r/min

cm3 (cu. in) mm (in) kPa (kgf/cm2, psi)

In-line, 4 stroke, DOHC, 16 valves 4 1,741 (106.2) 79.0 × 88.8 (3.11 × 3.50) 9.7 950 (9.5, 135) Electronic fuel injection Fuel injection Electric TCI 12, 25 LFR6A-11 Water Through propeller boss Wet sump

V, A

Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders. The figures are reference only.

2-1

SPEC

GENERAL SPECIFICATIONS Item

Lubrication oil pressure at 55˚C (131˚F)

(without oil filter) Gear oil type Gear oil grade Gear oil total quantity

(*2)

Unleaded regular gasoline 86 91 4-stroke motor oil SE, SF, SG, SH, or SJ 10W-30 or 10W-40

API SAE L (US qt, lmp qt) L (US qt, lmp qt)

4.5 (4.76, 3.96) 4.3 (4.55, 3.78)

SAE cm3 (US oz, lmp oz)

BRACKET Trim angle (at 12˚ boat transom) Tilt-up angle Steering angle DRIVE UNIT Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark ELECTRICAL Battery minimum capacity(*3) CCA/SAE MCA/ABYC RC/SAE

LF115TR 350 (3.5, 49.8)

PON(*2) RON

Engine oil type Engine oil grade Engine oil capacity (with oil filter)

F115TR

kPa (kgf/cm2, psi) @ idling

FUEL AND OIL Fuel type Fuel rating

(*1)

Model

Unit (*1)

GEAR CASE LUBE 90 760 (25.7, 26.8) 715 (24.2, 25.2)

Degree

–4 - 16

Degree Degree

70 30 + 30 F-N-R 2.15 (28/13) Spiral bevel gear Dog clutch Spline Clockwise Counterclockwise K

A A Minute

380 502 124 (*3)

The figures are reference only. PON: Pump Octane Number = (RON + Motor Octane Number)/2 RON: Research Octane Number

2-2

CCA: Cold Cranking Ampere MCA: Marine Cranking Ampere ABYC: American Boat and Yacht Council SAE: Society of Automotive Engineers RC: Reserve Capacity

SPEC

MAINTENANCE SPECIFICATIONS

POWER UNIT Item CYLINDER HEADS Warpage limit

(lines indicate straightedge position) Camshaft journal inside diameter CYLINDERS Bore size Taper limit Out-of-round limit PISTONS Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance <Limit> Oversize piston diameter PISTON PINS Outside diameter PISTON RINGS Top ring Dimension B B Dimension T T End gap Side clearance 2nd ring B Dimension B Dimension T T End gap Side clearance Oil ring Dimension B B Dimension T T End gap Side clearance

Model

Unit

F115TR

LF115TR

mm (in)

0.1 (0.004)

mm (in)

25.000 - 25.021 (0.984 - 0.985)

mm (in) mm (in) mm (in)

79.000 - 79.020 (3.110 - 3.111) 0.08 (0.003) 0.05 (0.002)

mm (in) mm (in) mm (in) mm (in) mm (in)

78.928 - 78.949 (3.1074 - 3.1082) 13 (0.51) 0.070 - 0.080 (0.0028 - 0.0031) 0.13 (0.005) 79.25 (3.120)

mm (in)

17.997 - 18.000 (0.7085 - 0.7087)

mm (in) mm (in) mm (in) mm (in)

1.17 - 1.19 (0.046 - 0.047) 2.80 - 3.00 (0.110 - 0.118) 0.15 - 0.30 (0.006 - 0.012) 0.04 - 0.08 (0.002 - 0.003)

mm (in) mm (in) mm (in) mm (in)

1.47 - 1.49 (0.058 - 0.059) 3.00 - 3.20 (0.118 - 0.126) 0.70 - 0.90 (0.028 - 0.035) 0.03 - 0.07 (0.001 - 0.003)

mm (in) mm (in) mm (in) mm (in)

2.38 - 2.48 (0.094 - 0.098) 2.40 (0.094) 0.20 - 0.70 (0.008 - 0.028) 0.03 - 0.15 (0.001 - 0.006)

2-3

SPEC

MAINTENANCE SPECIFICATIONS Item

CAMSHAFTS Intake (A) A Exhaust (A) Intake and B exhaust (B) Camshaft journal diameter Camshaft journal oil clearance Maximum camshaft runout VALVES Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust A Face width (B) Intake B Exhaust Seat width (C) Intake C Exhaust Margin thickness (D) Intake D Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake Exhaust Stem runout limit

E Model

Unit

F115TR

LF115TR

mm (in) mm (in) mm (in)

37.22 - 37.38 (1.465 - 1.472) 36.90 - 37.06 (1.453 - 1.459) 29.92 - 30.08 (1.178 - 1.184)

mm (in) mm (in) mm (in)

24.96 - 24.98 (0.9827 - 0.9835) 0.020 - 0.061 (0.0008 - 0.0024) 0.03 (0.0012)

mm (in) mm (in)

0.20 ± 0.03 (0.008 ± 0.001) 0.34 ± 0.03 (0.013 ± 0.001)

mm (in) mm (in)

29.0 - 29.2 (1.14 - 1.15) 24.0 - 24.2 (0.94 - 0.95)

mm (in) mm (in)

2.00 - 2.43 (0.079 - 0.096) 2.28 - 2.71 (0.090 - 0.107)

mm (in) mm (in)

1.2 - 1.6 (0.047 - 0.063) 1.2 - 1.6 (0.047 - 0.063)

mm (in) mm (in)

0.8 - 1.2 (0.031 - 0.047) 1.0 - 1.4 (0.039 - 0.055)

mm (in) mm (in)

5.975 - 5.990 (0.2352 - 0.2358) 5.960 - 5.975 (0.2346 - 0.2352)

mm (in)

6.000 - 6.018 (0.2362 - 0.2369)

mm (in) mm (in) mm (in)

0.015 - 0.043 (0.0006 - 0.0017) 0.030 - 0.058 (0.0012 - 0.0023) 0.01 (0.0004)

2-4

SPEC

MAINTENANCE SPECIFICATIONS Item

VALVE SPRINGS Free length Minimum free length Tilt limit VALVE LIFTERS Valve lifter outside diameter Valve-lifter-to-cylinder-head clearance VALVE PADS Valve pad thickness (in 0.025 mm increments) CONNECTING RODS Small-end inside diameter Big-end inside diameter Big-end oil clearance Big-end bearing thickness Yellow Green Blue Red CRANKSHAFT Crankshaft journal Diameter Minimum diameter Crankshaft pin Diameter Runout limit

E Model

Unit

F115TR

LF115TR

mm (in) mm (in) mm (in)

53.20 (2.094) 52.25 (2.057) 2.6 (0.10)

mm (in) mm (in)

27.965 - 27.980 (1.1010 - 1.1016) 0.020 - 0.056 (0.0008 - 0.0022)

mm (in)

2.000 - 3.300 (0.0787 - 0.1299)

mm (in) mm (in) mm (in)

17.965 - 17.985 (0.7073 - 0.7081) 45.025 - 45.045 (1.7726 - 1.7734) 0.025 - 0.031 (0.0010 - 0.0012)

mm (in) mm (in) mm (in) mm (in)

1.502 - 1.508 (0.0591 - 0.0593) 1.508 - 1.514 (0.0593 - 0.0596) 1.514 - 1.520 (0.0596 - 0.0598) 1.520 - 1.526 (0.0598 - 0.0601)

mm (in) mm (in)

47.984 - 48.000 (1.8891 - 1.8898) 47.972 (1.8887)

mm (in) mm (in)

41.982 - 42.000 (1.6528 - 1.6535) 0.03 (0.001)

2-5

SPEC

MAINTENANCE SPECIFICATIONS Item

CRANKCASE Crankcase main journal inside diameter Crankshaft journal oil clearance Upper crankcase main journal bearing thickness Green Blue Red Lower crankcase main journal bearing thickness Yellow Green Blue Red No. 3 main journal bearing thickness Green Blue Red OIL PUMP Discharge at 100 ˚C (212 ˚F), with 10W-30 engine oil Pressure Relief valve opening pressure THERMOSTATS Opening temperature Full-open temperature

Valve open lower limit ENGINE SPEED Idling speed

E Model

Unit

F115TR

LF115TR

mm (in)

54.023 - 54.042 (2.1269 - 2.1276)

mm (in)

0.024 - 0.044 (0.0009 - 0.0017)

mm (in) mm (in) mm (in)

2.992 - 2.999 (0.1178 - 0.1181) 2.999 - 3.006 (0.1181 - 0.1183) 3.006 - 3.013 (0.1183 - 0.1186)

mm (in) mm (in) mm (in) mm (in)

3.010 - 3.017 (0.1185 - 0.1188) 3.017 - 3.024 (0.1188 - 0.1191) 3.024 - 3.031 (0.1191 - 0.1193) 3.031 - 3.038 (0.1193 - 0.1196)

mm (in) mm (in) mm (in)

2.992 - 2.999 (0.1178 - 0.1181) 2.999 - 3.006 (0.1181 - 0.1183) 3.006 - 3.013 (0.1183 - 0.1186)

L (US gal, Imp gal)/min @ 1,000 r/min kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)

5.9 (1.56, 1.30)

118 (1.18, 16.78)

˚C (˚F) ˚C (˚F)

48 - 52 (118 - 126) 60 (140)

mm (in)

4.3 (0.17)

r/min

750 ± 50

2-6

490 (4.90, 69.69)

SPEC

MAINTENANCE SPECIFICATIONS

LOWER UNIT Item

Model

Unit

F115TR

GEAR BACKLASH Pinion - forward gear

mm (in)

Pinion - reverse gear

mm (in)

Pinion shims Forward gear shims Reverse gear shims

mm mm mm

LF115TR

0.19 - 0.53 0.31 - 0.66 (0.007 - 0.021) (0.012 - 0.026) 0.86 - 1.26 0.86 - 1.21 (0.034 - 0.050) (0.034 - 0.048) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

ELECTRICAL Item IGNITION SYSTEM Ignition timing ECM unit (B/R, B/W – B) Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min Pulser coil (W/R, W/B – B) Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min IGNITION CONTROL SYSTEM Engine cooling water temperature sensor Resistance (B/Y – B) @ 5˚C (41˚F) @ 20˚C (68˚F) @ 100˚C (212˚F) Throttle position sensor Output voltage (P – B)

Model

Unit

F115TR

LF115TR

Degree

4 ATDC - 20 BTDC

V V V V

5.0 122 242 245

V V V V

3.5 3.0 26 44

kΩ kΩ kΩ

4.62 2.44 0.19

0.732 ± 0.014

* Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-7

SPEC

MAINTENANCE SPECIFICATIONS Item

STARTING SYSTEM Fuse 1 Fuse 2 STARTER MOTOR Type Output Rating Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit CHARGING SYSTEM Lighting coil (W – W) Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min Rectifier/regulator (R – B) Output peak voltage lower limit @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min POWER TRIM AND TILT SYSTEM Trim sensor Resistance (P – B)

E Model

Unit

F115TR

LF115TR

V-A V-A

12-20 12-30

kW Second

Sliding gear 1.4 30

mm (in) mm (in)

15.5 (0.61) 9.5 (0.37)

mm (in) mm (in)

29.0 (1.14) 28.0 (1.10)

mm (in) mm (in)

0.5 - 0.8 (0.02 - 0.03) 0.2 (0.01)

V V V V

9.3 7.4 37 (open circuit voltage) 89 (open circuit voltage)

V V V V

— 7.5 12.5 13.0

Ω

9 - 378.8

* Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-8

SPEC

MAINTENANCE SPECIFICATIONS Item

POWER TRIM AND TILT MOTOR Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit

E Model

Unit

F115TR

LF115TR

ATF Dexron II mm (in) mm (in)

9.8 (0.39) 4.8 (0.19)

mm (in) mm (in)

22.0 (0.87) 21.0 (0.83)

mm (in) mm (in)

1.35 (0.05) 0.85 (0.03)

2-9

SPEC

MAINTENANCE SPECIFICATIONS

DIMENSIONS

L6 L2

H2 H7 H10

L8 B6

H4 A2 C3

H11

Symbol

L5 A1

A3 L4

Models F115TR

LF115TR

Degree

30 68.5

Degree

2.5

mm (in)

367 (14.4)

mm (in)

82 (3.2)

mm (in)

662 (26.1)

mm (in)

115 (4.5)

mm (in)

631 (24.8)

(L)

mm (in)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

1,122 (44.2)

mm (in)

555 (21.9)

mm (in)

81 (3.2) 1,005 (39.6)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

1,056 (41.6)

mm (in)

681 (26.8)

mm (in)

12 (0.5)

—

16 (0.6) 929 (36.6)

—

191 (7.5)

(L)

mm (in)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

850 (33.5)

mm (in)

404 (15.9)

mm (in)

31 (1.2)

mm (in)

879 (34.6)

H10

mm (in)

45 (1.8)

H11

mm (in)

14 (0.6)

mm (in)

246 (9.7)

mm (in)

388 (15.3)

mm (in)

660 (26.0)

—

137 (5.4)

mm (in)

—

104 (4.1)

(L)

2-10

Unit

516 (20.3)

—

643 (25.3) 773 (30.4)

—

SPEC

MAINTENANCE SPECIFICATIONS

A1 W5

L6 L2 L10

H2 H7

H10 H8

Symbol

B6 H4 H1 H3 H11

Unit

L5 L8 A3 L9

LF115TR

Degree

30 68.5

Degree

2.5

mm (in)

367 (14.4)

mm (in)

82 (3.2)

mm (in)

662 (26.1)

mm (in)

316 (12.4)

mm (in)

832 (32.8)

mm (in)

631 (24.8)

(L)

mm (in)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

1,122 (44.2)

mm (in)

555 (21.9)

mm (in)

81 (3.2) 1,005 (39.6)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

1,056 (41.6)

mm (in)

681 (26.8)

mm (in)

12 (0.5)

—

16 (0.6) 929 (36.6)

—

191 (7.5)

(L)

mm (in)

(X)

mm (in)

(L)

mm (in)

(X)

mm (in)

850 (33.5)

mm (in)

404 (15.9)

mm (in)

105 (4.1)

mm (in)

879 (34.6)

H10

mm (in)

45 (1.8)

H11

mm (in)

14 (0.6)

mm (in)

246 (9.7)

mm (in)

93 (3.7)

mm (in)

388 (15.3)

mm (in)

574 (22.6)

—

294 (11.6)

mm (in)

—

104 (4.1)

(L)

2-11

Models F115TR

516 (20.3)

—

643 (25.3) 773 (30.4)

—

SPEC

MAINTENANCE SPECIFICATIONS

Symbol

Unit

Models F115TR

LF115TR

mm (in)

254 (10.0)

mm (in)

163.5 (6.4)

mm (in)

50.8 (2.0)

mm (in)

180 (7.1)

mm (in)

367 (14.4)

mm (in)

18.5 (0.7)

mm (in)

82 (3.2)

mm (in)

13 (0.5)

mm (in)

55.5 (2.2)

2-12

125.4 (4.9)

SPEC

TIGHTENING TORQUES

SPECIFIED TORQUES Part to be tightened

Thread size

POWER UNIT Flywheel magnet assembly Positive battery lead Power unit mount Driven sprocket Drive sprocket Timing belt tensioner Spark plug Cylinder head cover Breather cover Fuel pump bracket assembly Camshaft cap Cylinder head assembly Cylinder head assembly (1.5 mm thread pitch) Exhaust cover

M24 M8 M8 M10 M40 M10 M14 M6 M4 M7 1st 2nd 1st 2nd 1st 2nd 3rd 1st 2nd

Oil filter Oil pressure switch Crankcase Crankcase (1.5 mm thread pitch) Connecting rod cap LOWER UNIT Propeller Trim tab Lower unit Impeller housing Shift rod assembly Ring nut Drive shaft housing assembly Pinion nut Gear oil drain screw Gear oil level check screw

M7 M8 M10 M6 — —

1st 2nd 1st 2nd 1st 2nd

M8 M10 M8 M18 M10 M10 M8 M6 M101.5 M8 M16 — —

2-13

Nm 186 9 42 60 265 40 25 8 2 17 8 17 14 28 15 30 6 12 18 8 14 28 19 15

55 43 37 18 8 105 18 93 7 7

Tightening torques m•kgf ft•lb 19 0.9 4.2 6.0 27 4.0 2.5 0.8 0.2 1.7 0.8 1.7 1.4 2.8 1.5 3.0 Turn 90˚ 0.6 1.2 1.8 0.8 1.4 2.8 1.9 Turn 60˚ 1.5 Turn 60˚

137 6.5 30 43 192 29 18 5.8 1.4 12 5.8 12 10 20 11 22

5.5 4.3 3.7 1.8 0.8 10.5 1.8 9.3 0.7 0.7

40 31 27 13 5.8 76 13 67 5.1 5.1

4.3 8.7 13 5.8 10 20 14 11

SPEC

TIGHTENING TORQUES Part to be tightened

BRACKET UNIT Friction piece Steering handle assembly Main switch assembly Engine stop lanyard switch Shift lever Steering handle bracket Shift rod detent mechanism screw Oil pump Upper mount Lower mount Muffler assembly Exhaust manifold Oil pan Oil strainer Clamp bracket Cam Trim stopper POWER TRIM AND TILT UNIT Power trim and tilt reservoir Power trim and tilt motor Manual valve Tilt ram end screw Gear pump unit Gear pump Trim ram end screw

Thread size

E Tightening torques Nm m•kgf ft•lb

— — — — M8 M10 — M6 M12 M14 M8 M6 M6 M6 M22 — —

13 38 5 4 18 38 18 10 53 73 20 11 11 11 15 2 37

1.3 3.8 0.5 0.4 1.8 3.8 1.8 1.0 5.3 7.3 2.0 1.1 1.1 1.1 1.5 0.2 3.7

9.4 27.5 3.7 2.9 13 27.5 13 7.2 38 53 14 8.0 8.0 8.0 11 1.4 27

1/4” 1/4” — — 5/16” — —

5 5 4 130 9 6 80

0.5 0.5 0.4 13 0.9 0.6 8.0

3.6 3.6 2.9 94 6.5 4.3 52

2-14

SPEC

TIGHTENING TORQUES

Nut (A)

Bolt (B)

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

GENERAL TORQUES

General torque specifications Nm mâ&#x20AC;˘kgf ftâ&#x20AC;˘lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

2150

2-15

INSP ADJ

CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............................................................. 3-1 TOP COWLING ............................................................................................... 3-2 CHECKING THE TOP COWLING FIT ....................................................... 3-2 FUEL SYSTEM ................................................................................................ 3-2 CHECKING THE FUEL LINE ..................................................................... 3-2 CHECKING THE FUEL FILTER ................................................................. 3-3 MEASURING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) ............................................................... 3-3 CONTROL SYSTEM........................................................................................ 3-4 CHECKING AND ADJUSTING THE THROTTLE BODY PICKUP TIMING ...................................................................................... 3-4 ADJUSTING THE SHIFT CABLE.............................................................. 3-5 ADJUSTING THE THROTTLE CABLE ..................................................... 3-6 ADJUSTING THE THROTTLE POSITION SENSOR................................ 3-7 SYNCHRONIZING THE THROTTLE VALVES.......................................... 3-8 ADJUSTING THE THROTTLE POSITION SENSOR (WHEN DISASSEMBLING OR REPLACING THE THROTTLE BODY)................................................................................. 3-10 COOLING SYSTEM ...................................................................................... 3-11 CHECKING THE COOLING WATER DISCHARGE ................................ 3-11 POWER UNIT ................................................................................................ 3-11 CHECKING THE ENGINE OIL LEVEL..................................................... 3-11 REPLACING THE ENGINE OIL/OIL FILTER ........................................... 3-11 CHECKING THE TIMING BELT .............................................................. 3-12 ADJUSTING THE VALVE CLEARANCE ................................................ 3-13 POWER TRIM AND TILT SYSTEM .............................................................. 3-16 CHECKING THE POWER TRIM AND TILT FLUID LEVEL ..................... 3-16 ADJUSTING THE TRIM SENSOR CAM ................................................ 3-17

INSP ADJ LOWER UNIT ................................................................................................ 3-18 CHECKING THE GEAR OIL LEVEL ........................................................ 3-18 CHANGING AND CHECKING THE GEAR OIL ...................................... 3-18 CHECKING THE LOWER UNIT (FOR AIR LEAKS) ................................ 3-20 GENERAL ...................................................................................................... 3-20 CHECKING THE ANODES...................................................................... 3-20 CHECKING THE BATTERY..................................................................... 3-21 CHECKING THE SPARK PLUGS............................................................ 3-22 COMPRESSION PRESSURE MEASUREMENT .................................... 3-23 OIL PRESSURE MEASUREMENT ......................................................... 3-24 LUBRICATION POINTS.......................................................................... 3-25

1 2 3 4 5 6 7 8 9

INSP ADJ

MAINTENANCE INTERVAL CHART

Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Item

Remarks

10 hours 50 hours 100 hours 200 hours (Break-in) (3 months) (6 months) (1 year)

TOP COWLING Top cowling fit Check FUEL SYSTEM Fuel line Check Fuel filter Check/replace POWER UNIT Water leakage Check Motor exterior Check Engine oil Replace Oil filter Replace (*1) Timing belt Check/replace (*2) Valve clearance Check/adjust Thermostat Check Exhaust leakage Check (*3) Cooling water passage Flush CONTROL SYSTEM Remote control shift cable Check/adjust Remote control throttle Check/adjust cable Throttle position sensor Check/adjust POWER TRIM AND TILT UNIT Power trim and tilt fluid Check LOWER UNIT Gear oil Change Lower unit leakage Check Propeller(s) Check GENERAL Anodes Check/replace Battery Check/charge Spark plugs Clean/adjust/ replace Wiring and connectors Adjust/reconnect (*4) Bolts and nuts Tighten Lubrication points Grease (*1) (*2) (*3) (*4)

Every

Refer to page

3-2 3-2 3-3

Every 400 hours (2 years)

— — 3-11 3-11 3-12 3-13 5-25 — — 3-5 3-6 3-7 3-16 3-18 3-20 6-3, 6-28 3-20 3-21 3-22 — — 3-25

Be sure replace the timing belt after every 1,000 hours or 5 years (whichever comes first) of operation. If leaded gasoline is usually used, engine valves and related parts should be inspected after every 300 hours of operation in addition to the items on the maintenance chart above. The engine should be flushed with fresh water after operating in salt, turbid or muddy water. Except for the cylinder head bolts and crankcase journal bolts. 3-1

INSP ADJ

TOP COWLING/FUEL SYSTEM TOP COWLING CHECKING THE TOP COWLING FIT

E 3

1. Check: • Top cowling fitting Loose/unlatched → Adjust the top cowling hook.

3010

2. Adjust: • Top cowling hook position 2

Adjustment steps (1) Loosen the bolts 1. (2) Move the top cowling hook 2 either up or down slightly (only a few millimeters). (3) Secure the bolts. (4) Check the top cowling fitting and repeat the adjustment if necessary.

1 3020

NOTE: • Moving the latch towards the seal will loosen the top cowling. • Moving the latch away from the seal will tighten the top cowling.

FUEL SYSTEM CHECKING THE FUEL LINE

1. Check: • High-pressure fuel line Cracks/damage/leaks → Replace. Refer to “HIGH-PRESSURE FUEL LINE” on page 4-8.

3030

3-2

INSP ADJ

FUEL SYSTEM

E 2. Check: • Plastic locking tie Loosen → Retighten or replace. 3. Check: • Low-pressure fuel line Cracks/damage/leaks → Replace. Refer to “LOW-PRESSURE FUEL LINE” on page 4-26.

3040

CHECKING THE FUEL FILTER

Check: • Fuel filter element • Fuel filter cup Clogs/cracks/leaks → Replace. Foreign matter → Clean. Refer to “FUEL FILTER” on page 4-29. 3050

MEASURING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE)

Measure: • Fuel pressure (high-pressure fuel line) Out of specification → Check the highpressure fuel line. Fuel pressure (high-pressure fuel line) 300 kPa (3.0 kg/cm2, 44.1 psi) Measuring steps (1) Install the fuel pressure gauge onto the pressure check valve. Fuel pressure gauge ................. 1 YB-06766 / 90890-06786 (2) Turn the main switch to on, and then measure the fuel pressure.

3060

3-3

INSP ADJ

CONTROL SYSTEM

CHECKING AND ADJUSTING THE THROTTLE BODY PICKUP TIMING

1. Check: • Throttle body pickup timing Incorrect → Adjust. Checking steps (1) Turn the throttle control lever to the full retard position. (2) Check that the mark a on the throttle cam aligns with the center of the throttle roller 1 as shown.

3100

2 5

2. Adjust: • Throttle body pickup timing

Adjustment steps (1) Loosen the nut 1. (2) Remove the throttle joint link rod 2. (3) Move the throttle control lever 3 until it contacts the fully-closed stopper 4.

NOTE: Make sure the throttle is fully-closed.

a 4

(4) Align the fully-closed mark a on the throttle control lever 3 with the center of the throttle roller 5 as shown. (5) Adjust the length of the throttle joint link rod until b is 0.5 mm. (6) Tighten the nut and install the throttle joint link rod onto the throttle control lever. (7) Move the throttle control lever to check that the throttle valve opens and closes smoothly. Also, make sure the throttle roller aligns with the fullyopen position c on the accelerator cam. (8) Set the throttle to the fully-closed position and check that the fully-closed mark a aligns with the center of the throttle roller.

3110

3-4

INSP ADJ

CONTROL SYSTEM

ADJUSTING THE SHIFT CABLE

1. Check: • Shift operation Incorrect → Adjust. 2. Adjust: • Shift cable joint position

a c

Adjustment steps (1) Align the mark a on the bushing with the mark b on the bracket c. (2) Loosen the locknut 1 and remove the clip 2. (3) Remove shift cable joint 3 from the set pin. (4) Position the remote control lever in the neutral position. (5) Adjust the position of the shift cable joint until it aligns with the set pin.

3120

3130

WARNING The shift cable joint must be screwed in at least 8 mm (0.31 in). (6) Install the shift cable joint onto the set pin. (7) Install the clip and tighten the locknut. (8) Move the remote control lever to the forward, neutral, and reverse positions and make sure it shifts smoothly and correctly. If the shifting operation is unsmooth or incorrect, repeat the above procedure.

3140

3. Check: • Shift operation Unsmooth operation → Repair.

3-5

INSP ADJ

CONTROL SYSTEM

ADJUSTING THE THROTTLE CABLE

1. Check: • Fully closed position Incorrect → Adjust. Checking steps (1) Fully close the throttle. (2) Check that the throttle control lever 1 touches the fully-closed stopper 2. 2

2. Adjust: • Throttle cable joint position

1 3

Adjustment steps (1) Contact the throttle control lever 1 with the fully-closed stopper 2. (2) Loosen the locknut 3 and remove the clip 4. (3) Remove throttle cable joint 5 from the set pin a. (4) Position the remote control lever in the neutral position. (5) Adjust the position of the throttle cable joint until it aligns with the set pin.

3150

WARNING The throttle cable joint must be screwed in at least 8 mm (0.31 in). (6) Install the throttle cable joint onto the set pin. (7) Install the clip and tighten the locknut. (8) Open and close the throttle (at the remote control) several times and make sure the throttle valves open and close smoothly and correctly. If the throttle operation is unsmooth or incorrect, repeat the above procedure.

3160

3-6

INSP ADJ

CONTROL SYSTEM

ADJUSTING THE THROTTLE POSITION SENSOR

1. Measure: • Throttle position sensor output voltage Out of specification → Adjust. Throttle position sensor output voltage (pink (P) – black (B)) 0.732 ± 0.014 V NOTE: • Be sure to adjust the throttle valve’s opening before measuring the throttle position sensor output voltage. • When measuring the throttle position sensor output voltage, set the digital tester to the manual range.

Measuring steps (1) Remove the intake silencer. Refer to “INTAKE ASSEMBLY” on page 4-3. (2) Disconnect the throttle joint link rod 1 at the throttle body. (3) Check the throttle valve. (4) Connect the test harness (3-pin) as shown.

3170

Test harness (3-pin) 90890-06793 3180

(5) Connect the digital tester probes to the test harness (3-pin) as shown. (6) Turn the engine start switch on. (7) Measure the output voltage. (8) Install the intake silencer. (9) Start the engine and measure the output voltage again.

3-7

INSP ADJ

CONTROL SYSTEM 2. Adjust: • Throttle position sensor

B PO

Adjustment steps (1) Loosen the screws 2. (2) Adjust the position of the throttle position sensor until the specified output voltage is obtained.

P O

1 3190

Throttle position sensor output voltage (pink (P) – black (B)) 0.732 ± 0.014 V General adjusting tool Torx T-20 (with a concave in the center) (3) Tighten the screws. (4) Connect the throttle joint link rod 1.

SYNCHRONIZING THE THROTTLE VALVES

CAUTION: Do not adjust the throttle valve when it is operating properly. Excess adjustment may cause poor engine performance.

Adjustment steps (1) Remove all of the blind plugs 1. (2) Connect the adaptors 2 and vacuum gauge 3 to the intake manifold assembly as shown. 3 Vacuum gauge set YU-08030 / 90890-03094

(3) Start the engine and allow it to warm up for several minutes. (4) Connect the tachometer to the spark plug lead of cylinder #1.

Tachometer YU-08036-A / 90890-06760 Engine idling speed 750 ± 50 r/min 3161

3-8

INSP ADJ

CONTROL SYSTEM

E (5) Check the vacuum pressure of all cylinders. (6) Turn the synchronizing screw 4 so the vacuum pressure of cylinder #3 or #4 is within 30 mmHg (40 mbar, 1.18 inHg) based of the vacuum pressure of cylinder #1 or #2. Tighten

Vacuum pressure increases.

Loosen

Vacuum pressure decreases.

General adjusting tool Torx T-25 (with a concave in the center) Example 1: Check results: Cylinder #1

360 mmHg (480 mbar, 14.2 inHg)

Cylinder #2

350 mmHg (467 mbar, 13.8 inHg)

Cylinder #3

310 mmHg (413 mbar, 12.2 inHg)

Cylinder #4

Adjust the difference of the vacuum pressure between cylinders #1 and #4 within 30 mmHg (40 mbar, 1.18 inHg).

300 mmHg (400 mbar, 11.8 inHg)

Example 2: Check results: Cylinder #1

Cylinder #2

Cylinder #3

Cylinder #4

3-9

360 mmHg (480 mbar, 14.2 inHg) 350 mmHg (467 mbar, 13.8 inHg) 390 mmHg (520 mbar, 15.4 inHg) 400 mmHg (533 mbar, 15.8 inHg)

Adjust the difference of the vacuum pressure between cylinders #2 and #4 within 30 mmHg (40 mbar, 1.18 inHg).

INSP ADJ

CONTROL SYSTEM

ADJUSTING THE THROTTLE POSITION SENSOR (WHEN DISASSEMBLING OR REPLACING THE THROTTLE BODY)

Adjusting steps (1) Install the intake assembly with the intake silencer removed. (2) Disconnect the throttle position sensor coupler. (3) Install the test harness to the throttle position sensor coupler. Test harness 90890-06793 (4) Connect the digital circuit tester. 1

Digital tester J-39299 / 90890-06752

2 3162

(5) Turn the main switch to on. (6) Loosen the synchronizing screw and fully open the lower side throttle valve (#3, 4). (7) Loosen the idling screw 1 and fully close the upper side throttle valve (#1, 2). (8) Adjust the position of the throttle position sensor until the output voltage is 0.7 ± 0.01 V and operate the throttle valve several times. (9) Record the value. (10) Slowly tighten the synchronizing screw 2 until the recorded value is changed. (11) Slowly tighten the idling screw until 0.032 ± 0.004 V increase over the recorded value. (12) Operate the throttle valve several times. (13) Install the throttle roller d as the mark e aligns with center of the throttle roller and check that the output voltage is not change. (14) Install the intake silencer. (15) Start the engine. (16) If the output voltage of the throttle position sensor is not within 0.732 ± 0.014 V, adjust the throttle position sensor. (17) Check that the throttle valve is synchronized.

3163

3-10

INSP ADJ

COOLING SYSTEM/POWER UNIT

COOLING SYSTEM CHECKING THE COOLING WATER DISCHARGE

Check: • Cooling water discharge No discharge → Clean and check the cooling water passage. 3200

Checking steps (1) Place the lower unit in water. (2) Start the engine. (3) Check that water flows from the cooling water outlet.

POWER UNIT CHECKING THE ENGINE OIL LEVEL a

Check: • Engine oil level Above a → Check for fuel in the engine oil. Below b → Add engine oil so that the level is between a and b.

3210

REPLACING THE ENGINE OIL/OIL FILTER 1. Remove: • Oil filler cap 1 • Drain plug 2 2. Remove: • Oil filter 3

1 3

Oil filter wrench YU-38411 / 90890-01426

3220

3. Install: • Drain plug 2

3230

3-11

Drain plug 28 Nm (2.8 m • kgf, 20 ft • lb)

INSP ADJ

POWER UNIT

E 4. Install: • Oil filter 3

Oil filter 18 Nm (1.8 m • kgf, 13.3 ft • lb)

NOTE: Lubricate the rubber seal with engine oil before installation.

3240

5. Add: • Engine oil Recommended engine oil 4 stroke motor oil API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40 Oil quantity with oil filter 4.5 L (4.76 US qt, 3.96 Imp qt) without oil filter 4.3 L (4.55 US qt, 3.78 Imp qt)

3250

6. Install: • Oil filler cap 7. Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-11. NOTE: • Run the engine for several minutes and then check the engine oil level. • If the engine oil is still not within the proper level, add/drain as needed.

CHECKING THE TIMING BELT Check: • Timing belt Wear/damage → Replace.

3260

3-12

INSP ADJ

POWER UNIT

ADJUSTING THE VALVE CLEARANCE

NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature.

1 3

1. Remove: • Flywheel magnet cover • Spark plug cap cover 1 2. Disconnect: • Spark plug leads 2 • Fuel hoses 3 • Ventilation hose • Vacuum hose 3. Loosen: • Timing belt tensioner 4. Remove: • Timing belt • Driven sprockets • Cylinder head cover • Spark plugs 5. Install: • Driven sprockets • Timing belt 6. Tighten: • Timing belt tensioner

2 3270

7. Measure: • Intake valve clearance a • Exhaust valve clearance b

Valve clearance Intake 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust 0.34 ± 0.03 mm (0.013 ± 0.001 in)

NOTE: If any valve clearance is out of specification, record its measurement.

3280

3-13

INSP ADJ

POWER UNIT

E Measurement steps (1) Turn the flywheel magneto clockwise until cylinder #1’s piston is at TDC. (2) Measure the intake valve clearance for cylinders #1 and #2. (3) Measure the exhaust valve clearance for cylinders #1 and #3. (4) Turn the flywheel magneto 360˚ clockwise. (5) Measure the intake valve clearance for cylinders #3 and #4. (6) Measure the exhaust valve clearance for cylinders #2 and #4.

3290

8. Loosen: • Timing belt tensioner 9. Remove: • Timing belt • Driven sprockets • Camshaft caps • Camshafts Refer to “POWER UNIT” on page 5-4.

10. Adjust: • Valve clearance NOTE: • Do not mix the valve train parts (i.e., valve pads, camshaft caps, camshafts). Keep them organized in their proper groups (e.g., cylinder #1 parts kept together). • Install the removed parts in their original positions. If valve train parts are installed in the wrong position, proper valve adjustments are impossible.

3-14

INSP ADJ

POWER UNIT

E Adjustment steps (1) Insert a thin screwdriver into the notch in the valve lifter. (2) Carefully pry up the valve pad and remove it. (3) Measure the thickness removed valve pad with a micrometer. (4) Select a proper replacement valve pad by calculating its thickness with the following formula. Proper valve pad thickness = Removed valve pad thickness + Measured valve clearance – Specified valve clearance (5) Install the proper valve pad into the valve lifter. NOTE: • Measure the thickness of the new valve pad with a micrometer because the thickness number is not indicated on the pad. • Lubricate the valve pad with molybdenum disulfide grease. • Perform the above procedure for all valves whose clearances are out of specification.

11. Install: • Camshafts • Camshaft caps • Driven sprockets • Timing belt 12. Tighten: • Timing belt tensioner Refer to “POWER UNIT” on page 5-4. 13. Recheck: • Valve clearance NOTE: If any valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

3-15

INSP ADJ

POWER UNIT/POWER TRIM AND TILT SYSTEM

14. Loosen: • Timing belt tensioner 15. Remove: • Driven sprockets • Timing belt 16. Tighten: • Timing belt tensioner 17. Install: • Cylinder head cover • Driven sprockets • Timing belt • Spark plugs 18. Connect: • Vacuum hose • Ventilation hose • Fuel hoses • Spark plug leads 19. Install: • Spark plug cap cover • Flywheel magneto cover

POWER TRIM AND TILT SYSTEM CHECKING THE POWER TRIM AND TILT FLUID LEVEL

Check: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. Recommended power trim and tilt fluid ATF Dexron II

WARNING When removing the power trim and tilt reservoir cap, the power trim and tilt fluid may spurt out due to internal pressure. Therefore, fully tilt up the outboard (the tilt ram assembly fully extended) and then slowly remove the power trim and tilt reservoir cap. 3300

3-16

INSP ADJ

POWER TRIM AND TILT SYSTEM

Checking steps (1) Tilt the outboard all the way up and lock it with the tilt stop levers 1.

WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.

3310

(2) Remove the reservoir cap 2 and check the fluid level. NOTE: The fluid level should be directly below the check hole as shown. (3) Add power trim and tilt fluid if needed, and then install the reservoir cap.

3320

Reservoir cap 8 Nm (0.8 m • kgf, 5.8 ft • lb)

ADJUSTING THE TRIM SENSOR CAM 1. Measure: • Trim sensor setting resistance Out of specification → Adjust. Trim sensor setting resistance Pink (P) – Black (B) 10 ± 1 Ω at 20 ˚C (68 ˚F) Measuring steps (1) Fully tilt the outboard down. (2) Measure the trim sensor resistance.

3323

3-17

INSP ADJ

POWER TRIM AND TILT SYSTEM/LOWER UNIT 2. Adjust: • Trim sensor cam position

Adjusting steps (1) Fully tilt the outboard down. (2) Loosen the screw 1. (3) Adjust the position of the trim sensor cam 2 until the specified resistance is obtained.

1 3325

Trim sensor resistance Pink (P) – Black (B) 9 – 378.8 Ω at 20 ˚C (68 ˚F) (4) Tighten the screw.

Trim sensor cam screw 2 Nm (0.2 m • kgf, 1.4 ft • lb)

LOWER UNIT CHECKING THE GEAR OIL LEVEL

Check: • Gear oil level Level is low → Add gear oil to the proper level.

CHANGING AND CHECKING THE GEAR OIL

1. Check: • Gear oil Milky oil → Replace the oil seal. Slag oil → Check the gears, bearings, and clutch dog. Checking steps (1) Tilt up the outboard slightly. (2) Place a container under the gear oil drain screw 1. (3) Remove the gear oil drain screw and gear oil level check screw 2.

3330

3-18

INSP ADJ

LOWER UNIT

E 2. Fill: • Gear oil (with the specified amount of the recommend gear oil) Recommended gear oil GEAR CASE LUBE SAE: 90 Total amount Regular rotation models 760 cm3 (25.7 US oz, 26.8 Imp oz) Counter rotation models 715 cm3 (24.2 US oz, 25.2 Imp oz)

Filling steps (1) Place the outboard in an upright position. (2) Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. (3) Install the gear oil level check screw and then quickly install the gear oil drain screw.

3340

3-19

Gear oil level check screw 7 Nm (0.7 m • kgf, 5.1 ft • lb) Gear oil drain screw 7 Nm (0.7 m • kgf, 5.1 ft • lb)

INSP ADJ

LOWER UNIT/GENERAL

CHECKING THE LOWER UNIT (FOR AIR LEAKS)

Check: • Lower unit holding pressure Pressure drops → Check the seals and components. Lower unit holding pressure 70 kPa (0.7 kg/cm2, 10.0 psi) Checking steps

CAUTION: Do not overpressurize the lower unit. Excessive pressure may damage the oil seals. (1) Remove the gear oil level check screw. (2) Install the pressure tester into the check hole.

3350

Pressure tester YB-35956 / 90890-06762 (3) Apply the specified pressure. NOTE: The lower unit should hold the specified pressure for 10 seconds.

GENERAL CHECKING THE ANODES

Check: • Anodes 1 • Trim tab 2 Scales → Clean. Grease/oil → Clean. Excessive wear → Replace. 1

CAUTION: Do not oil, grease or paint the anode, or it will not operate properly.

2 1 3360

3-20

INSP ADJ

GENERAL

CHECKING THE BATTERY

WARNING Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN - Flush with water. • EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): • Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures: • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.). • DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.

NOTE: • Batteries vary among manufacturers. Therefore, the following procedures may not always apply. Consult your battery manufacturer’s instructions. • First, disconnect the negative lead, then the positive lead.

3-21

INSP ADJ

GENERAL

E Check: • Electrolyte level Below the minimum level mark → Add distilled water to the proper level. • Electrolyte specific gravity Less than specification → Recharge the battery. Electrolyte specific gravity 1.280 at 20˚C (68˚F)

CHECKING THE SPARK PLUGS

1. Check: • Electrodes 1 Cracks/excessive wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition. 2. Clean: • Spark plug (with a spark plug cleaner or wire brush.)

3370

3. Measure: • Spark plug gap a Out of specification → Regap. Spark plug gap 1.0 - 1.1 mm (0.039 - 0.043 in) a 3380

3-22

INSP ADJ

GENERAL

E 4. Tighten: • Spark plug

Spark plug 25 Nm (2.5 m • kgf, 18 ft • lb)

NOTE: • Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti-seize compound to the spark plug threads to prevent thread seizure. • If a torque wrench is not available, a good estimate of the correct tightening torque is to finger tighten a the spark plug and then tighten it another 1/4 to 1/2 of a turn b.

3390

COMPRESSION PRESSURE MEASUREMENT

CAUTION: Before removing a spark plug, use compressed air to blow away dirt accumulated in the spark plug well to prevent it from falling into the cylinder that is being tested. 1. Check: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-13. 2. Warm-up: • Engine 3. Remove: • Spark plug(-s) 4. Install: • Compression gauge 1 (into the spark plug hole) 1

NOTE: Use a compression gauge that is used for automobiles. 3391

3-23

INSP ADJ

GENERAL

E 5. Measure: • Compression pressure Below minimum compression pressure → Inspect valve clearance, valve face, valve seat, piston rings, cylinder sleeve, piston, cylinder head gasket and cylinder head. Compression pressure (reference data) Minimum 950 kPa (9.5 kg/cm2, 135 psi) Measurement steps (1) Remove the lock plate from the engine stop lanyard switch on the remote control box. (2) With the throttle wide open, crank the engine setting the main switch in the START position until the reading on the compression gauge stabilizes. 6. Remove: • Compression gauge 7. Install: • Spark plug(-s)

OIL PRESSURE MEASUREMENT

1. Warm-up: • Engine 2. Remove: • Oil pressure switch

3392

3. Install: • Oil pressure gauge 1 (into the oil pressure switch hole)

NOTE: Use a pressure gauge with the range of 0 to 10 kg/cm2 and an adopter with a PT 1/4 thread.

3-24

INSP ADJ

GENERAL

E 4. Measure: • Oil pressure Out of specification → Check the oil pump, oil suction pipe and oil strainer. Oil pressure (reference data) At idling (55 ˚C (131 ˚F)) 350 kPa (3.5 kg/cm2, 49.8 psi) or higher 5. Remove: • Oil pressure gauge 6. Install: • Oil pressure switch

LUBRICATION POINTS

3400

1. Apply: • Water resistant grease

3410

3420

3-25

INSP ADJ

GENERAL

3430

3440

3450

2. Apply: â&#x20AC;¢ Corrosion resistant grease

3451

3-26

FUEL

CHAPTER 4 FUEL SYSTEM INTAKE SILENCER ......................................................................................... 4-1 REMOVING/INSTALLING THE INTAKE SILENCER................................ 4-1 INTAKE ASSEMBLY ....................................................................................... 4-3 REMOVING/INSTALLING THE INTAKE ASSEMBLY ............................. 4-3 THROTTLE BODY ........................................................................................... 4-5 REMOVING/INSTALLING THE THROTTLE BODY ................................. 4-5 CONTROL UNIT.............................................................................................. 4-6 REMOVING/INSTALLING THE CONTROL UNIT .................................... 4-6 HIGH-PRESSURE FUEL LINE......................................................................... 4-8 REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE ............... 4-8 REDUCING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE) .... 4-10 CHECKING THE PRESSURE REGULATOR........................................... 4-11 FUEL INJECTORS ......................................................................................... 4-12 REMOVING/INSTALLING THE FUEL INJECTORS ............................... 4-12 DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS .................. 4-13 FUEL HOSES................................................................................................. 4-14 REMOVING/INSTALLING THE FUEL HOSES....................................... 4-14 VAPOR SEPARATOR.................................................................................... 4-15 REMOVING/INSTALLING THE VAPOR SEPARATOR .......................... 4-15 DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR ............. 4-16 HIGH-PRESSURE FUEL PUMP .................................................................... 4-17 DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL PUMP ........................................................................................... 4-17 PRESSURE REGULATOR ............................................................................. 4-18 REMOVING/INSTALLING THE PRESSURE REGULATOR ................... 4-18

FUEL IDLE SPEED CONTROL ASSEMBLY ........................................................... 4-19 REMOVING/INSTALLING THE IDLE SPEED CONTROL ASSEMBLY.. 4-19 DISASSEMBLING/ASSEMBLING THE IDLE SPEED CONTROL ASSEMBLY............................................................................................ 4-21 FUEL RAIL ..................................................................................................... 4-22 DISASSEMBLING/ASSEMBLING THE FUEL RAIL............................... 4-22 INTAKE MANIFOLD...................................................................................... 4-23 DISASSEMBLING/ASSEMBLING THE INTAKE MANIFOLD ............... 4-23 THROTTLE POSITION SENSOR .................................................................. 4-24 REMOVING/INSTALLING THE THROTTLE POSITION SENSOR ........ 4-24 INSTALLING THE THROTTLE POSITION SENSOR ............................. 4-25 LOW-PRESSURE FUEL LINE ....................................................................... 4-26 REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE.............. 4-26 DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE.............................................................................................. 4-28 FUEL FILTER ................................................................................................. 4-29 DISASSEMBLING/ASSEMBLING THE FUEL FILTER........................... 4-29 FUEL PUMP .................................................................................................. 4-30 DISASSEMBLING/ASSEMBLING THE FUEL PUMP ............................ 4-30 CHECKING THE FUEL PUMPS .............................................................. 4-31

1 2 3 4 5 6 7 8 9

FUEL

INTAKE SILENCER

REMOVING/INSTALLING THE INTAKE SILENCER

8 × 20 mm

2 3 1

7 12

6 × 105 mm

5 8 6 × 20 mm 4015

Order

1 2 3 4 5 6

Job/Part Flywheel cover Plastic locking tie Hose Hose Intake air temperature sensor coupler Intake air temperature sensor Bolt

Q’ty

1 1 1 1

Remarks Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1. Not reusable (cylinder head cover-to-intake silencer) (vapor separator-to-intake silencer)

1 2 Continued on next page.

4-1

FUEL

INTAKE SILENCER

E 4

8 × 20 mm

2 3 1

7 12

6 × 105 mm

5 8 6 × 20 mm 4010

Order 7 8 9 10 11 12

Job/Part Collar Bolt Intake silencer O-ring Bolt Bracket

Q’ty 2 6 1 2 2 1

Remarks

For installation, reverse the removal procedure.

4-2

FUEL

INTAKE ASSEMBLY

REMOVING/INSTALLING THE INTAKE ASSEMBLY

6 × 20 mm

18 3

16 15 4 8 × 40 mm

8 13 14 1

6 15 17

8 × 120 mm

11 10

4010

Order

1 2 3 4 5 6 7 8 9

Job/Part Intake silencer Throttle joint link rod Throttle position sensor coupler Idle speed control valve coupler Intake air pressure sensor coupler Fuel injector coupler High-pressure fuel pump coupler Bolt Bolt Bolt

Q’ty

Remarks Refer to “INTAKE SILENCER” on page 4-1.

1 1 1 1 4 1 4 4 1 Continued on next page. 4-3

FUEL

INTAKE ASSEMBLY

E 4

6 × 20 mm

18 3

16 15 4 8 × 40 mm

8 13 14 1

15 17

8 × 120 mm

11 10

4010

Order 10 11 12 13 14 15 16 17 18 19 20

Job/Part Washer Collar Plastic locking tie Hose clamp Fuel filter assembly Hose clamp Water hose Water hose Hose Intake assembly Gasket

Q’ty 1 1 1 1 1 2 1 1 1 1 1

4-4

Remarks

Not reusable

(fuel cooler-to-water outlet) (fuel cooler-to-exhaust cover)

Not reusable For installation, reverse the removal procedure.

FUEL

THROTTLE BODY

REMOVING/INSTALLING THE THROTTLE BODY

8 4 3 8 × 70 mm

2 5

6 × 20 mm

4030

Order

Job/Part Intake assembly

Q’ty

1 2 3 4 5 6 7 8

Bolt Bracket Bolt Throttle body #1 Spring Throttle joint link rod Throttle body #2 O-ring

4 2 6 1 1 1 1 4

4-5

Remarks Refer to “INTAKE ASSEMBLY” on page 4-3.

2.46 × 48 mm For installation, reverse the removal procedure.

FUEL

CONTROL UNIT

REMOVING/INSTALLING THE CONTROL UNIT

8 14

10 SS LT

9 13 12 11

5 7

2 6 SS LT

4 3 1

Order

Job/Part Intake silencer

Q’ty

1 2 3 4 5 6 7

Bolt Collar Wave washer Washer Throttle control lever Spring Washer

1 1 1 1 1 1 1

6 × 30 mm

4020

Remarks Refer to “INTAKE SILENCER” on page 4-1.

Continued on next page.

4-6

FUEL

CONTROL UNIT

E 4

8 14

10 SS LT

9 13 12 11

5 7

2 6 SS LT

4 3 1

Order 8 9 10 11 12 13 14

Job/Part Throttle joint link rod Nut Collar Wave washer Washer Accelerator cam Stud bolt

Q’ty 1 1 1 1 1 1 1

6 × 30 mm

Remarks

For installation, reverse the removal procedure.

4-7

4020

FUEL

HIGH-PRESSURE FUEL LINE

REMOVING/INSTALLING THE HIGH-PRESSURE FUEL LINE

6 × 10 mm

4 6

6 × 30 mm

6 × 25 mm

8 15 11 10 8 × 45 mm

Order

1 2 3 4 5 6 7 8

Job/Part Intake assembly Bolt Washer Vapor separator Plastic locking tie Bolt Washer Fuel cooler Collar

Q’ty

3 3 1 2 2 2 1 2

4040

Remarks Refer to “INTAKE ASSEMBLY” on page 4-3.

Not reusable

Continued on next page.

4-8

FUEL

HIGH-PRESSURE FUEL LINE

E 4

6 × 10 mm

4 6

6 × 30 mm

6 × 25 mm

8 15 11 10 8 × 45 mm

Order 9 10 11 12 13 14 15 16

Job/Part Hose Bolt Washer Bolt Washer Fuel rail Collar Collar

Q’ty 1 2 2 1 1 1 2 1

4040

Remarks (intake manifold-to-pressure regulator)

For installation, reverse the removal procedure.

4-9

FUEL

HIGH-PRESSURE FUEL LINE REDUCING THE FUEL PRESSURE (HIGH-PRESSURE FUEL LINE)

WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 1. Reduce: â&#x20AC;˘ Fuel pressure (high-pressure fuel line) Reducing steps (1) Remove the cap 1. (2) Cover the pressure check valve a of the fuel rail with a rag, and then press in the valve using a thin screwdriver 2 to release the fuel pressure.

WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. (3) Remove the cap 3, and then press in the valve b using a thin screwdriver 2. (4) Place a container under the vapor separator, and then drain the fuel from the separator by removing the drain screw 4.

4-10

FUEL 4060

HIGH-PRESSURE FUEL LINE

CHECKING THE PRESSURE REGULATOR

Check: • Pressure regulator Faulty → Replace the pressure regulator. Checking steps (1) Install the fuel pressure gauge onto the pressure check valve. Fuel pressure gauge ................. 1 YB-06766 / 90890-06786 (2) Main switch to on. (3) Check the fuel pressure. Fuel pressure Approx. 300 kPa (3.0 kg/cm2, 44.1 psi) (4) Start the engine. (5) Check the fuel pressure. Fuel pressure Approx. 250 kPa (2.5 kg/cm2, 35.6 psi)

4-11

FUEL

FUEL INJECTORS

REMOVING/INSTALLING THE FUEL INJECTORS

2 6

8 × 45 mm

5 4070

Order

1 2 3 4 5 6

Job/Part High-pressure fuel line

Bolt Washer Fuel cooler Collar Fuel injector coupler Fuel injector

Q’ty

Remarks Refer to “HIGH-PRESSURE FUEL LINE” on page 4-8. Before performing the following procedure, reduce the fuel pressure (high-pressure fuel line).

2 2 1 2 4 4 For installation, reverse the removal procedure. 4-12

FUEL

FUEL INJECTORS

E 4

DISASSEMBLING/ASSEMBLING THE FUEL INJECTORS

2 3 4 4080

Order Job/Part 1 Rubber seal 2 Rubber damper 3 O-ring

Q’ty 1 1 1

4-13

Remarks

2.2 × 7.8 mm For assembly, reverse the disassembly procedure.

FUEL

FUEL HOSES

REMOVING/INSTALLING THE FUEL HOSES

2 4

1 2 3

2 1 5

4100

Order

1 2 3 4 5

Job/Part High-pressure fuel line

Hose clamp Hose clamp Fuel hose Fuel hose Fuel hose

Q’ty

2 4 1 1 1

4-14

Remarks Refer to “HIGH-PRESSURE FUEL LINE” on page 4-8. Before performing the following procedure, reduce the fuel pressure (high-pressure fuel line). Not reusable (vapor separator-to-fuel rail) (pressure regulator-to-fuel cooler) (fuel cooler-to-vapor separator) For installation, reverse the removal procedure.

FUEL

VAPOR SEPARATOR

REMOVING/INSTALLING THE VAPOR SEPARATOR

6 × 30 mm 4110

Order 1 2 3 4

Job/Part Fuel hoses Bolt Washer Hose Vapor separator

Q’ty 3 3 1 1

Remarks Refer to “FUEL HOSES” on page 4-14.

(vapor separator-to-intake silencer) For installation, reverse the removal procedure.

4-15

FUEL

VAPOR SEPARATOR

E 4

DISASSEMBLING/ASSEMBLING THE VAPOR SEPARATOR 3 4 × 16 mm

4120

Order 1 2 3 4 5 6 7 8

Job/Part Drain screw Gasket Screw O-ring Float chamber Holder High-pressure fuel pump filter Vapor separator body

Q’ty 1 1 7 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

4-16

FUEL

HIGH-PRESSURE FUEL PUMP

DISASSEMBLING/ASSEMBLING THE HIGH-PRESSURE FUEL PUMP

7 6

3 × 8 mm

8 2 4130

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Float pin Float Needle valve Screw Retainer Collar O-ring High-pressure fuel pump Grommet High-pressure fuel pump connector

Q’ty 1 1 1 1 1 1 1 1 1 1

Remarks

1.35 × 7 mm

For assembly, reverse the disassembly procedure. 4-17

FUEL

PRESSURE REGULATOR

REMOVING/INSTALLING THE PRESSURE REGULATOR

3 5 2 1 4

6 × 12 mm

4140

Order

Job/Part

Q’ty

Fuel rail

1 2 3 4 5 6

Hose clamp Hose Hose Screw Pressure regulator O-ring

1 1 1 2 1 1

4-18

Remarks Refer to “HIGH-PRESSURE FUEL LINE” on page 4-8. Before performing the following procedure, reduce the fuel pressure (high-pressure fuel line) (fuel cooler-to-pressure regulator) (intake manifold-to-pressure regulator)

1.8 × 8 mm For installation, reverse the removal procedure.

FUEL

IDLE SPEED CONTROL ASSEMBLY

REMOVING/INSTALLING THE IDLE SPEED CONTROL ASSEMBLY

10 6 × 24 mm

6 5

4 6 × 60 mm

6 8

Order

Job/Part Intake assembly

4150

Q’ty

Hose

2 3 4 5 6

Bolt Washer Bolt Washer Hose clamp

1 1 2 2 4

Remarks Refer to “INTAKE ASSEMBLY” on page 4-3. (idle speed control assembly-to-intake silencer)

Continued on next page.

4-19

FUEL

IDLE SPEED CONTROL ASSEMBLY

E 4

10 6 × 24 mm

6 5

4 6 × 60 mm

6 8

Order Job/Part 7 Vacuum hose

4150

Q’ty 1

Hose

Idle speed control assembly

Remarks (idle speed control assembly-to-intake manifold) (idle speed control assembly-to-throttle body #2) (idle speed control assembly-to-throttle body #1) For installation, reverse the removal procedure.

4-20

FUEL

IDLE SPEED CONTROL ASSEMBLY

E 4

DISASSEMBLING/ASSEMBLING THE IDLE SPEED CONTROL ASSEMBLY

4 × 12 mm

5 × 6 mm

5 2 3

7 4160

Order 1 2 3 4 5 6 7 8

Job/Part Screw Pressure sensor O-ring Screw Idle speed control O-ring Filter Idle speed control body

Q’ty 2 1 1 3 1 1 1 1

Remarks

1.9 × 14.8 mm

2 × 29 mm

For assembly, reverse the disassembly procedure.

4-21

FUEL

FUEL RAIL

DISASSEMBLING/ASSEMBLING THE FUEL RAIL

4 3

2 5 × 10 mm

Order

Job/Part Fuel injectors

4170

Q’ty

Fuel hoses Pressure regulator 1 2 3 4 5

Cap Screw Fuel rail joint O-ring Fuel rail

1 2 1 1 1

Remarks Refer to “FUEL INJECTORS” on page 4-12. Refer to “FUEL HOSES” on page 4-14. Refer to “PRESSURE REGULATOR” on page 4-18.

2.4 × 12 mm For assembly, reverse the disassembly procedure.

4-22

FUEL

INTAKE MANIFOLD

DISASSEMBLING/ASSEMBLING THE INTAKE MANIFOLD

4180

Order

Job/Part Throttle body High-pressure fuel line

Q’ty

Idle speed control assembly 1

Hose

2 3 4 5

Collar Grommet Rubber seal Intake manifold

6 3 4 1

Remarks Refer to “THROTTLE BODY” on page 4-5. Refer to “HIGH-PRESSURE FUEL LINE” on page 4-8. Refer to “IDLE SPEED CONTROL ASSEMBLY” on page 4-19. (pressure regulator-to-intake manifold-toidle speed control assembly)

For assembly, reverse the disassembly procedure. 4-23

FUEL

THROTTLE POSITION SENSOR

REMOVING/INSTALLING THE THROTTLE POSITION SENSOR

4190

Order Job/Part 1 Throttle position sensor connector 2 Screw 3 Throttle position sensor

Qâ&#x20AC;&#x2122;ty 1

Remarks

2 1 For installation, reverse the removal procedure.

4-24

FUEL

THROTTLE POSITION SENSOR

INSTALLING THE THROTTLE POSITION SENSOR NOTE: During installation, make sure the throttle position sensor is properly adjusted. Install: • Throttle position sensor Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 3-7.

4-25

FUEL

LOW-PRESSURE FUEL LINE

REMOVING/INSTALLING THE LOW-PRESSURE FUEL LINE

6 × 28 mm

1 5

6 × 28 mm 6 × 20 mm

6 × 16 mm

3 4

6 × 35 mm

10 8

12 9

6 × 16 mm

4200

Order 1 2 3 4 5 6 7 8 9

Job/Part Bolt Grommet retaining plate Bolt Plate Bolt Clamp plate Bolt Screw Plug cover

Q’ty 2 1 1 1 1 1 1 5 1

Remarks

Continued on next page.

4-26

FUEL

LOW-PRESSURE FUEL LINE

E 4

6 × 28 mm

1 5

6 × 28 mm 6 × 20 mm

6 × 16 mm

3 4

6 × 35 mm

10 8

12 9

6 × 16 mm

4200

Order 10 11 12 13 14 15 16

Job/Part Bolt O-ring Plastic locking tie Hose Plastic locking tie Fuel hose joint Low-pressure fuel line

Q’ty 2 1 1 1 1 1 1

Remarks 3.1 × 29.4 mm Not reusable Not reusable

For installation, reverse the removal procedure.

4-27

FUEL

LOW-PRESSURE FUEL LINE

E 4

DISASSEMBLING/ASSEMBLING THE LOW-PRESSURE FUEL LINE

1 4 1

4210

Order 1 2 3 4 5

Job/Part Plastic locking tie Fuel hose Fuel filter Fuel hose Fuel pump

Qâ&#x20AC;&#x2122;ty 4 1 1 1 1

Remarks Not reusable (hose joint-to-fuel filter) (fuel pump-to-fuel filter) For assembly, reverse the disassembly procedure.

4-28

FUEL

FUEL FILTER

DISASSEMBLING/ASSEMBLING THE FUEL FILTER

4 6 5

4220

Order 1 2 3 4 5 6 7 8

Job/Part Nut Fuel filter bracket Fuel filter cup O-ring Fuel filter element O-ring Float Fuel filter cap

Q’ty 1 1 1 1 1 1 1 1

Remarks

2.0 × 32.2 mm Not reusable 1.5 × 13.5 mm Not reusable

For assembly, reverse the disassembly procedure.

4-29

FUEL

FUEL PUMP

DISASSEMBLING/ASSEMBLING THE FUEL PUMP

1 6 × 35 mm LT

572

3 2

4 5 9

10 11 8 7 6

Order 1 2 3 4 5 6 7 8 9 10 11

4230

Job/Part Screw Nut Fuel pump cover Gasket Fuel pump body Pin Plunger Spring Diaphragm Spring Fuel pump cover

Q’ty 3 2 1 1 1 1 1 1 1 1 1

Remarks

Not reusable

For assembly, reverse the disassembly procedure. 4-30

FUEL

FUEL PUMP

CHECKING THE FUEL PUMPS

1. Check: • Diaphragm • Fuel pump valves Damage → Replace. 2. Check: • Fuel pump Reverse air flow → Replace. Checking steps

NOTE: Do not overpressurize the fuel pump. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the fuel pump as shown.

Mity vac YB-35956 / 90890-06756 (2) Apply the specified pressure with the Mity vac.

Fuel pump pressure a 50 kPa (0.5 kg/cm2, 7.1 psi) Fuel pump negative pressure b 30 kPa (0.3 kg/cm2, 4.3 psi) 4240

NOTE: • Make sure no air comes out of the opposite side of the fuel pump. • To eliminate any gaps between the fuel pump valves and the fuel pump body, and to ensure a better seal, make sure the inside of the fuel pump is wet (i.e., with gas).

4-31

POWR

CHAPTER 5 POWER UNIT FLYWHEEL MAGNET ASSEMBLY ................................................................ 5-1 REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ...... 5-1 REMOVING THE FLYWHEEL MAGNET ASSEMBLY ............................. 5-2 INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ........................... 5-3 POWER UNIT .................................................................................................. 5-4 DISCONNECTING/CONNECTING THE CONTROL CABLE .................... 5-4 DISCONNECTING/CONNECTING THE LEADS ...................................... 5-6 REMOVING/INSTALLING THE POWER UNIT ........................................ 5-8 STATOR COIL ASSEMBLY ............................................................................ 5-9 REMOVING/INSTALLING THE STATOR COIL ASSEMBLY................... 5-9 TIMING BELT ................................................................................................ 5-10 REMOVING/INSTALLING THE TIMING BELT ...................................... 5-10 REMOVING THE DRIVEN SPROCKET .................................................. 5-12 REMOVING/INSTALLING THE DRIVE SPROCKET............................... 5-12 INSTALLING THE DRIVEN SPROCKET................................................. 5-13 INSTALLING THE TIMING BELT ........................................................... 5-13 IGNITION COILS AND STARTER MOTOR .................................................. 5-14 REMOVING/INSTALLING THE IGNITION COILS AND STARTER MOTOR................................................................................. 5-14 ECM AND JUNCTION BOX ASSEMBLY..................................................... 5-15 REMOVING/INSTALLING THE CDI UNIT AND JUNCTION BOX ASSEMBLY ............................................................... 5-15 DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY............................................................................................ 5-18 CYLINDER HEAD COVER ............................................................................. 5-20 REMOVING/INSTALLING THE CYLINDER HEAD COVER ................... 5-20 CAMSHAFTS ................................................................................................ 5-21 REMOVING/INSTALLING THE CAMSHAFTS....................................... 5-21 CHECKING THE CAMSHAFT................................................................. 5-22 INSTALLING THE CAMSHAFT.............................................................. 5-22

POWR

CYLINDER HEAD ASSEMBLY ..................................................................... 5-23 REMOVING/INSTALLING THE CYLINDER HEAD ASSEMBLY............ 5-23 CHECKING THE THERMOSTAT ............................................................ 5-25 VALVES......................................................................................................... 5-26 REMOVING/INSTALLING THE VALVES ............................................... 5-26 CHECKING THE VALVE ......................................................................... 5-28 CHECKING THE VALVE SPRING........................................................... 5-29 CHECKING THE CYLINDER HEAD ........................................................ 5-29 CHECKING THE VALVE GUIDE ............................................................. 5-29 CHECKING THE VALVE SEAT ............................................................... 5-30 INSTALLING THE VALVE ...................................................................... 5-31 OIL FILTER AND EXHAUST COVER............................................................ 5-32 REMOVING/INSTALLING THE OIL FILTER AND EXHAUST COVER .. 5-32 INSTALLING THE OIL FILTER ............................................................... 5-35 CRANKSHAFT AND PISTON/CONNECTING ROD ASSEMBLY................ 5-36 REMOVING/INSTALLING THE CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY.......................................................... 5-36 CHECKING THE CYLINDER BLOCK ...................................................... 5-38 CHECKING THE PISTON........................................................................ 5-38 CALCULATING THE PISTON-TO-CYLINDER CLEARANCE................. 5-39 CHECKING THE PISTON RING.............................................................. 5-39 CHECKING THE CRANKSHAFT............................................................. 5-40 CHECKING THE MAIN-BEARING OIL CLEARANCE ............................ 5-40 CHECKING THE CONNECTING ROD BIG-END OIL CLEARANCE....... 5-43 INSTALLING THE PISTON RING........................................................... 5-46 INSTALLING THE PISTON..................................................................... 5-47

1 2 3 4 5 6 7 8 9

POWR

FLYWHEEL MAGNET ASSEMBLY

REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY

8 × 20 mm

1 186 Nm (19 m • kgf, 137 ft • Ib)

5 6

2 3 3 2

2 4

5010

Order 1 2 3 4 5 6 7 8

Job/Part Bolt Collar Grommet Flywheel cover Flywheel magnet nut Washer Flywheel magnet assembly Woodruff key

Q’ty 2 4 2 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

5-1

POWR

FLYWHEEL MAGNET ASSEMBLY

CAUTION: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel holder may easily slip off.

5020

REMOVING THE FLYWHEEL MAGNET ASSEMBLY

1. Remove: • Flywheel magnet assembly nut Flywheel magnet assembly holder YB-06139 / 90890-06522 Å For USA and Canada ı For worldwide

5030

2. Remove: • Flywheel magnet assembly

Universal puller YB-06117 / 90890-06521 Å For USA and Canada ı For worldwide

CAUTION:

5040

• Keep the nut side flush with the crankshaft end until the flywheel magnet assembly comes off the tapered portion of the crankshaft. • To prevent damage to the engine or tools, screw in the universal-puller setbolts evenly and completely so that the universal-puller plate is parallel to the flywheel magnet assembly.

5050

5-2

POWR

FLYWHEEL MAGNET ASSEMBLY

INSTALLING THE FLYWHEEL MAGNET ASSEMBLY

Install: • Flywheel magnet assembly nut Flywheel magnet assembly holder YB-06139 / 90890-06522 5060

Å For USA and Canada ı For worldwide

ı T.

5070

5-3

Flywheel magnet assembly nut 186 Nm (19.0 m • kgf, 137 ft • lb)

POWR

POWER UNIT

DISCONNECTING/CONNECTING THE CONTROL CABLE

6 × 30 mm

1 2 6 × 20 mm

3 4

8 6 × 20 mm

6 9 7 5 10

5080

Order

Job/Part Battery leads

Q’ty

Low-pressure fuel line 1 2 3 4 5

Bolt Grommet retaining plate Bolt Hose locating plate Clip

Remarks Disconnect the leads form the battery terminals. Refer to “LOW-PRESSURE FUEL LINE” on page 4-26.

2 1 1 1 2 Continued on next page.

5-4

POWR

POWER UNIT

E 5

6 × 30 mm

1 2 6 × 20 mm

3 4

8 6 × 20 mm

6 9 7 5 10

5080

Order 6 7 8 9 10

Job/Part Bolt Cable clamp Grommet Throttle control cable Shift control cable

Q’ty 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

5-5

POWR

POWER UNIT

E 5

DISCONNECTING/CONNECTING THE LEADS

6 × 10 mm

8 6 7

9 Nm (0.9 m • kgf, 6.5 ft • Ib)

4 5

6 × 20 mm

12 6 × 10 mm

13 15

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part Junction box cover Wire harness coupler Warning lamp coupler Bolt Negative battery lead Nut Washer Positive battery lead Bolt PTT motor lead (sky blue) Bolt

Q’ty 1 1 1 1 1 1 2 1 1 1 1

5090

Remarks For the remote control box.

Continued on next page.

5-6

POWR

POWER UNIT

E 5

6 × 10 mm

8 6 7

9 Nm (0.9 m • kgf, 6.5 ft • Ib)

4 5

6 × 20 mm

12 6 × 10 mm

13 15

Order 12 13 14 15 16 17 18 19 20

Job/Part PTT motor lead (light green) Plastic locking tie Flushing water hose Plastic locking tie Hose clamp Pilot water hose Hose clamp Pilot water hose Oil level dipstick

Q’ty 1 1 1 1 1 1 1 1 1

5090

Remarks Not reusable (exhaust cover-to-hose joint) Not reusable (fuel cooler-to-exhaust cover) (fuel cooler-to-water outlet) For installation, reverse the removal procedure.

5-7

POWR

POWER UNIT

E 5

REMOVING/INSTALLING THE POWER UNIT

6 8 9 3 6 × 16 mm

572

2 5

6 × 40 mm

6 8 × 35 mm

Order 1 2 3 4 5 6 7 8 9

42 Nm (4.2 m • kgf, 30 ft • Ib) 10 × 130 mm

Job/Part Bolt Nut Bolt Apron Bolt Bolt Power unit Gasket Dowel pin

5100

572

Q’ty 2 2 5 1 6 2 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

5-8

POWR

STATOR COIL ASSEMBLY

REMOVING/INSTALLING THE STATOR COIL ASSEMBLY

6 × 28 mm

4 × 8 mm

6 8 6 × 28 mm

3 6 × 16 mm

Order

1 2 3 4 5 6 7 8 9

Job/Part Flywheel magnet assembly Stator coil coupler Rectifier/regulator connector Bolt Screw Bolt Lighting coil assembly Pulser coil connector Bolt Base

5110

Q’ty

Remarks Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-1.

1 1 1 1 3 1 1 4 1 For installation, reverse the removal procedure. 5-9

POWR

TIMING BELT

REMOVING/INSTALLING THE TIMING BELT

5120

Order

1 2 3 4 5 6 7 8

Job/Part Stator coil assembly Bolt Flywheel cover bracket Plastic locking tie Hose clamp Hose Driven sprocket bolt Washer Driven sprocket

Q’ty

2 1 1 1 1 2 2 2

Remarks Refer to “STATOR COIL ASSEMBLY” on page 5-9.

Not reusable

Continued on next page.

5-10

POWR

TIMING BELT

E 5

5120

Order 9 10 11 12 13 14 15 16 17

Job/Part Pin Drive sprocket nut Bolt Spring Timing belt tensioner Timing belt Drive sprocket Pick-up rotor Woodruff key

Qâ&#x20AC;&#x2122;ty 2 1 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

5-11

POWR

TIMING BELT

REMOVING THE DRIVEN SPROCKET

CAUTION: Make sure cylinder #1’s position is at TDC before removal. Remove: • Bolt 5130

Flywheel magnet assembly holder YB-06139 / 90890-06522 Å For USA and Canada ı For worldwide

REMOVING/INSTALLING THE DRIVE SPROCKET

1. Remove: • Nut Crankshaft holder YB-06552 / 90890-06552 5140

NOTE: A deep socket ( : 46 mm, 76 mm deep) is required for this service.

4 2. Install: • Woodruff key 1 • Pick-up rotor 2 • Drive sprocket 3 • Drive sprocket nut 4

Drive sprocket nut 265 Nm (27.0 m • kgf, 192 ft • lb)

Crankshaft holder YB-06552 / 90890-06552

5150

5-12

POWR

TIMING BELT

INSTALLING THE DRIVEN SPROCKET

Install: • Driven sprocket bolt

Driven sprocket bolt 60 Nm (6.0 m • kgf, 43 ft • lb)

Flywheel magnet assembly holder YB-06139 / 90890-06522

5160

Å For USA and Canada ı For worldwide

INSTALLING THE TIMING BELT

CAUTION: • Never forcefully twist, turn inside out, or bend the timing belt. • Do not let oil or grease get onto the timing belt. • A Minimum 25 mm (1.0 in)

A 5170

Install: • Timing belt • Tensioner Installation steps (1) Align ø6 hole on the pickup rotor with the notch in the cylinder block. (2) Align the marks “ ” on the driven sprockets with the top edge of the cylinder head. (3) Install the timing belt onto the driven sprockets and drive sprocket. (4) Install the tensioner.

Tensioner bolt 40 Nm (4.0 m • kgf, 29 ft • lb)

(5) Turn the crankshaft clockwise two times and make sure the drive sprocket and driven sprockets are correctly aligned with the marks.

5180

5-13

POWR

IGNITION COILS AND STARTER MOTOR

REMOVING/INSTALLING THE IGNITION COILS AND STARTER MOTOR

25 Nm (2.5 m • kgf, 18 ft • Ib) 10 6

5 Br/W 9

4 8 × 45 mm

8 7 1

R 6 × 30 mm

6 × 30 mm

5190

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Ignition coil coupler Bolt Ignition coil Spark plug Screw Relay (magnetic switch) lead Nut Wire harness lead Bolt Starter motor

Q’ty 2 4 2 4 1 1 1 2 3 1

Remarks

For installation, reverse the removal procedure.

5-14

POWR

ECM AND JUNCTION BOX ASSEMBLY

REMOVING/INSTALLING THE CDI UNIT AND JUNCTION BOX ASSEMBLY B

19 6 × 12 mm

15 14

26 16

27 23

8 4

24 6 × 16 mm

4 2 3

6 × 28 mm

1 11

13 6

17 6 × 28 mm 5200

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part ECM coupler Bolt ECM Collar Grommet Bolt Rectifier/regulator Bolt Ground lead Bolt Ground lead

6 × 16 mm

Q’ty 2 4 1 8 1 2 1 1 2 1 3

10 12

6 × 25 mm 6 × 16 mm

Remarks

Continued on next page.

5-15

POWR

ECM AND JUNCTION BOX ASSEMBLY

E 5

19 6 × 12 mm

15 14

26 B

27 23

8 4

24 6 × 16 mm

4 2 3

6 × 28 mm

1 11

13 6

17 6 × 28 mm 5200

Order Job/Part 12 Bolt 13 Ground lead 14 Water temperature sensor coupler 15 Bolt 16 Clamp 17 Bolt 18 Junction box assembly 19 Throttle position sensor coupler 20 Intake air pressure sensor coupler

6 × 16 mm

Q’ty 1 2 1

10 12

6 × 25 mm 6 × 16 mm

Remarks

2 2 5 1 1 1 Continued on next page.

5-16

POWR

ECM AND JUNCTION BOX ASSEMBLY

E 5

19 6 × 12 mm

15 14

27 23

8 4

24 6 × 16 mm

4 2 3

6 × 28 mm

1 11

13 6

17 6 × 28 mm 5200

Order 21 22 23 24 25 26 27 28

Job/Part Idle speed control valve coupler Fuel injectors coupler High-pressure fuel pump coupler Shift position switch coupler Plastic locking tie Plastic locking tie Connector Oil pressure switch coupler

6 × 16 mm

Q’ty 1 4 1 1 1 1 1 1

10 12

6 × 25 mm 6 × 16 mm

Remarks

Not reusable Not reusable

For installation, reverse the removal procedure.

5-17

POWR

ECM AND JUNCTION BOX ASSEMBLY

E 5

DISASSEMBLING/ASSEMBLING THE JUNCTION BOX ASSEMBLY

16 17

1 3 15

14 8

7 5

9 10

4 5210

Order 1 2 3 4 5 6 7 8 9

Job/Part Screw Main relay coupler Main relay Bolt PTT relay coupler PTT relay Screw Plate Screw

Q’ty 1 1 1 2 1 1 1 1 1

6 × 14 mm

Remarks

Continued on next page.

5-18

POWR

ECM AND JUNCTION BOX ASSEMBLY

E 5

16 17

1 3 15

14 8

7 5

9 18

10 11

4 5210

Order 10 11 12 13 14 15 16 17 18

Job/Part Positive battery lead Starter relay coupler Starter relay Screw Diagnostic coupler Fuse holder Clip Wire harness Junction box

Q’ty 1 1 1 1 1 4 1 1 1

6 × 14 mm

Remarks

For assembly, reverse the disassembly procedure.

5-19

POWR

CYLINDER HEAD COVER

REMOVING/INSTALLING THE CYLINDER HEAD COVER

17 Nm (1.7 m • kgf, 12 ft • Ib) 7 × 48 mm 2 Nm (0.2 m • kgf, 1.4 ft • Ib) 4 × 8 mm S1280B

572

4 3

Order 1 2 3 4 5 6 7 8

1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 2nd 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 6 × 30 mm

Job/Part Timing belt and driven sprockets Oil filler cap Bolt Cylinder head cover Rubber gasket Screw Breather cover Bolt Fuel pump bracket assembly

Q’ty

Remarks Refer to “TIMING BELT” on page 5-10.

1 14 1 1 8 1 2 1 For installation, reverse the removal procedure.

5-20

5220

POWR

CAMSHAFTS

REMOVING/INSTALLING THE CAMSHAFTS 1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 2nd 17 Nm (1.7 m • kgf, 12 ft • Ib) 7 × 48 mm

3 3

0 9

9 0 8

4 M

4 E E

7 8

6 5

2 1

7 × 37 mm 1st 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 2nd 17 Nm (1.7 m • kgf, 12 ft • Ib)

3 4

5230

Order

1 2 3 4 5 6

Job/Part Cylinder head cover Bolt Bolt Camshaft cap Camshaft cap Oil seal Camshaft

Q’ty

Remarks Refer to “CYLINDER HEAD COVER” on page 5-20.

16 4 2 8 2 2 For installation, reverse the removal procedure.

5-21

1 5 6 4 3

POWR

CAMSHAFTS

CHECKING THE CAMSHAFT

1. Measure: • Camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimension a IN: 37.22 - 37.38 mm (1.465 - 1.472 in) b IN: 29.92 - 30.08 mm (1.178 - 1.184 in) a EX: 36.90 - 37.06 mm (1.453 - 1.459 in) b EX: 29.92 - 30.08 mm (1.178 - 1.184 in)

2. Measure: • Camshaft journal diameter a • Camshaft cap inside diameter b Out of specification → Replace the camshaft or cylinder head.

5240

Camshaft journal diameter a: 24.96 - 24.98 mm (0.9827 - 0.9835 in) Camshaft cap inside diameter b: 25.000 - 25.021 mm (0.984 - 0.985 in)

b b

5250

INSTALLING THE CAMSHAFT 1

Install: • Camshaft • Camshaft cap

Installation steps (1) Before installing the exhaust and intake camshafts, turn the crankshaft until cylinder #1’s piston is at TDC on the compression stroke. (2) Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down.

5 5

5260

5-22

POWR

CYLINDER HEAD ASSEMBLY

REMOVING/INSTALLING THE CYLINDER HEAD ASSEMBLY

1st 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 30 Nm (3.0 m • kgf, 22 ft • Ib) 3rd 90° 70 Nm (7.0 m • kgf, 51 ft • Ib)* 10 × 145 mm 6 6 × 25 mm 8 × 25 mm

8 3

9 13

10 2

12 A

572

1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 8 × 55 mm

6 × 20 mm

Order

Job/Part

Q’ty

Camshafts Intake assembly 1 2 3 4 5

Bolt (1.5 mm thread pitch) Bolt Cylinder head assembly Gasket Dowel pin

10 5 1 1 2

5270

Remarks Refer to “CAMSHAFTS” on page 5-21. Refer to “INTAKE ASSEMBLY” on page 4-3.

Not reusable Continued on next page.

*: Torque value (for reference only)

5-23

POWR

CYLINDER HEAD ASSEMBLY

E 5

1st 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 30 Nm (3.0 m • kgf, 22 ft • Ib) 3rd 90° 70 Nm (7.0 m • kgf, 51 ft • Ib)* 10 × 145 mm 6 6 × 25 mm 8 × 25 mm

8 3

9 13

10 2

12 A

572

1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 8 × 55 mm

6 × 20 mm

Order 6 7 8 9 10 11 12 13

Job/Part Bolt Thermostat cover Thermostat Bolt Anode cover O-ring Bolt Anode

Q’ty 2 1 1 4 2 2 2 2

5270

Remarks

For installation, reverse the removal procedure.

5-24

POWR

CYLINDER HEAD ASSEMBLY

CHECKING THE THERMOSTAT

1. Check: • Thermostat Damage/valve does not open → Replace. 2. Measure: • Valve operating temperature • Valve lift a Out of specification → Replace the thermostat.

5280

Water temperature

Valve lift

Below 0 mm (0 in) 48 - 52˚C (118 - 126˚F) Above 60˚C (140˚F)

Min. 4.3 mm (0.17 in)

Measuring steps (1) Suspend the thermostat in a container filled with water. (2) Slowly heat the water. (3) Place a thermometer in the water. (4) While stirring the water, observe the thermometer’s indicated temperature.

5-25

POWR

VALVES

REMOVING/INSTALLING THE VALVES

1 2

3 4

6 7

10 8

7 E

6 5

4 3 2 1

Order

1 2 3 4 5

Job/Part Camshaft and cylinder head assembly Valve pad Valve lifter Valve cotter Spring retainer Valve spring

Q’ty

5290

Remarks Refer to “CAMSHAFTS” on page 5-21 and “CYLINDER HEAD ASSEMBLY” on page 5-23.

16 16 32 16 16 Continued on next page.

5-26

POWR

VALVES

E 5

1 2

3 4

6 7

10 8

7 E

6 5

4 3 2 1

Order 6 7 8 9 10

Job/Part Valve stem seal Spring seat Valve guide Intake valve Exhaust valve

Qâ&#x20AC;&#x2122;ty 16 16 16 8 8

Remarks

For installation, reverse the removal procedure.

5-27

5290

POWR

VALVES

CHECKING THE VALVE a

1. Check: • Valve Damage/warpage → Replace. 2. Measure: • Margin thickness a Out of specification → Replace. Margin thickness IN: 0.8 - 1.2 mm (0.031 - 0.047 in) EX: 1.0 - 1.4 mm (0.039 - 0.055 in)

5300

3. Measure: • Valve stem diameter a Out of specification → Replace.

Valve stem diameter IN: 5.975 - 5.990 mm (0.2352 - 0.2358 in) EX: 5.960 - 5.975 mm (0.2346 - 0.2352 in) 5310

4. Measure: • Valve stem runout Out of specification → Replace. Valve stem runout limit IN and EX 0.01 mm (0.0004 in) NOTE: The valve guide, valve seal, and valve should be replaced as a set.

5320

5-28

POWR

VALVES

CHECKING THE VALVE SPRING

1. Measure: • Free length a Out of specification → Replace. Free length limit 52.25 mm (2.057 in) 5330

2. Measure: • Valve spring tilt a Out of specification → Replace. Valve spring tilt limit IN and EX 2.6 mm (0.10 in)

5340

CHECKING THE CYLINDER HEAD

Measure: • Cylinder head warpage Out of specification → Reface or replace. Warpage limit 0.1 mm (0.004 in) 5350

CHECKING THE VALVE GUIDE

Measure: • Valve guide bore a Out of specification → Replace the guide.

Valve guide bore 6.000 - 6.018 mm (0.2362 - 0.2369 in)

5360

Replacement steps (1) Remove the valve guide with the valve guide remover/installer. Valve guide remover YM-4064-A / 90890-04064

5370

5-29

POWR

VALVES

E (2) Install the new valve guide to the specified position (from the top of the valve guide bore as shown) a with the valve guide remover/installer. Valve guide position 11.5 mm (0.45 in) (3) After installing the valve guide, bore the valve guide with the valve guide reamer.

5380

Valve guide reamer YM-04066 / 90890-04066 NOTE: • Heat the cylinder head in an oven to 200˚C (392˚F) to ease valve guide removal and installation, and to maintain the correct interference fit. • Before installing the valve guide, mark its installation position b as shown.

5390

CHECKING THE VALVE SEAT

1. Measure: • Valve seat width a Out of specification → Reface the valve seat. a

Valve seat width Intake 1.2 - 1.6 mm (0.047 - 0.063 in) Exhaust 1.2 - 1.6 mm (0.047 - 0.063 in)

5400

2. Reface: • Valve seat

CAUTION: To prevent chatter marks, turn the valve seat cutter while an even, downward pressure (4 - 5 kg).

5-30

POWR

VALVES

E Valve seat cutter set YM-91043-C / 90890-06803 Valve seat cutter holder YB-06553 / 90890-06553 Valve seat cutter (45˚) YB-06555 / 90890-06555 (90˚) YB-06556 / 90890-06556

• Refer to the following chart to determine the appropriate valve seat cutter.

5410

Valve seat area

Valve seat cutter

90˚

45˚

NOTE: After refacing the valve seat or replacing the valve and valve guide, lap the valve seat and valve face.

INSTALLING THE VALVE

1. Install: • Valve stem seal 1 • Valve 2 • Spring seat 3 • Valve spring 4 • Spring retainer 5 2. Install: • Valve cotter 6 Valve spring compressor YM-01253 / 90890-04019 Valve spring compressor adapter YB-06554 / 90890-06554 NOTE: Compress the valve spring with the special tools and install the cotters onto the valve. 5420

5-31

POWR

OIL FILTER AND EXHAUST COVER

REMOVING/INSTALLING THE OIL FILTER AND EXHAUST COVER

B H 7

14 × 12 mm

3 D 5

2 E 5

G 24

A 17

18 17

20 11

6 × 20 mm

10 2 14

7 16

9 8

18 Nm (1.8 m • kgf, 13 ft • Ib)

5430

13 6

1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 30 mm

3 LT

572 572

Order

Job/Part Camshafts and cylinder head assembly

Q’ty

1 2 3 4 5 6 7

Oil filter Oil filter stand Bolt Exhaust cover Gasket Bolt Pressure control valve (PCV) cover

1 1 18 1 1 3 1

6 × 16 mm 8 × 25 mm

6 × 20 mm

Remarks Refer to “CAMSHAFTS” on page 5-21 and “CYLINDER HEAD ASSEMBLY” on page 5-23.

Not reusable

Continued on next page.

5-32

POWR

OIL FILTER AND EXHAUST COVER

E 5

B H 7

14 × 12 mm

3 D 5

2 E 5

G 24

A 17

18 17

20 11

6 × 20 mm

10 2 14

7 16

9 8

18 Nm (1.8 m • kgf, 13 ft • Ib)

5430

10 11 12 13 14 15 16

1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 30 mm

Order Job/Part 8 Spring 9 Pressure control valve (PCV) Grommet Gasket Bolt Anode cover O-ring Bolt Anode

3 LT

572 572

Q’ty 1 1 1 1 2 1 1 1 1

6 × 16 mm 8 × 25 mm

6 × 20 mm

Remarks Face the longer side towards the cylinder block. Not reusable

Continued on next page.

5-33

POWR

OIL FILTER AND EXHAUST COVER

E 5

B H 7

14 × 12 mm

3 D 5

2 E 5

G 24

A 17

18 17

20 11

6 × 20 mm

10 2 14

7 16

9 8

18 Nm (1.8 m • kgf, 13 ft • Ib)

5430

1st 6 Nm (0.6 m • kgf, 4.3 ft • Ib) 2nd 12 Nm (1.2 m • kgf, 8.7 ft • Ib) 6 × 30 mm

Order Job/Part 17 Bolt 18 Metal clamp 19 Engine temperature sensor retainer 20 Engine temperature sensor 21 Gasket 22 Drain plug 23 Washer 24 Screw 25 Anode

3 LT

572 572

Q’ty 2 1 1 1 1 1 1 3 3

6 × 16 mm 8 × 25 mm

6 × 20 mm

Remarks

Not reusable

For installation, reverse the removal procedure.

5-34

POWR

OIL FILTER AND EXHAUST COVER INSTALLING THE OIL FILTER

E 5

Install: • Oil filter

Oil filter 18 Nm (1.8 m • kgf, 13 ft • lb)

Oil filter wrench YU-38411 / 90890-01426

5440

Refer to “REPLACING THE ENGINE OIL/OIL FILTER” on page 3-11.

5-35

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

POWR

CRANKSHAFT AND PISTON/CONNECTING ROD ASSEMBLY

REMOVING/INSTALLING THE CRANKSHAFT AND PISTON/CONNECTING ROD ASSEMBLY

8 Nm (0.8 m • kgf, 5.8 ft • Ib) 1st 19 Nm (1.9 m • kgf, 14 ft • Ib) 2nd 60° 50 Nm (5.0 m • kgf, 36 ft • Ib)* 10 × 135 mm

6 × 25 mm

14 6

10 E

11 5

11 E

1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 8 × 55 mm

11 11

1st 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 60° 8 × 38 mm

Order

Job/Part Oil filter and exhaust cover

Q’ty

1 2 3 4 5 6 7

Bolt Washer Bracket Oil pressure switch Bolt Bolt (1.5 mm thread pitch) Crankcase

4 2 2 1 10 10 1

5450

Remarks Refer to “OIL FILTER AND EXHAUST COVER” on page 5-32.

Continued on next page. *: Torque value (for reference only)

5-36

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

POWR

E 5

8 Nm (0.8 m • kgf, 5.8 ft • Ib) 1st 19 Nm (1.9 m • kgf, 14 ft • Ib) 2nd 60° 50 Nm (5.0 m • kgf, 36 ft • Ib)* 10 × 135 mm

6 × 25 mm

14 6

10 E

11 5

11 E

1st 14 Nm (1.4 m • kgf, 10 ft • Ib) 2nd 28 Nm (2.8 m • kgf, 20 ft • Ib) 8 × 55 mm

11 11

1st 15 Nm (1.5 m • kgf, 11 ft • Ib) 2nd 60° 8 × 38 mm

Order 8 9 10 11 12 13 14 15 16

Job/Part Connecting rod bolt Connecting rod cap Crankshaft Main bearing Big end bearing Piston/connecting rod assembly Oil seal Oil seal Cylinder block

Q’ty 8 4 1 5 4 4 1 1 1

Remarks Not reusable

For installation, reverse the removal procedure.

5-37

5450

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

CHECKING THE CYLINDER BLOCK

20 mm (0.8 in)

70 mm (2.8 in)

Cylinder bore “D” 120 mm (4.7 in)

Measure: • Cylinder bore Out of specification → Rebore the cylinder or replace the cylinder block. Standard

Wear limit

79.000 - 79.020 mm (3.110 - 3.111 in)

—

D1 and D2

Taper limit “T”

—

0.08 mm (0.003 in)

D3 and D4

Out of round limit

—

0.05 mm (0.002 in)

D = Maximum Dia. (D1 - D6) T = (maximum D1 or D2) – (minimum D5 or D6)

D5 and D6

5460

NOTE: Measure the cylinder bore in parallel and at a right angle to the crankshaft. Then, average the measurements.

CHECKING THE PISTON

Measure: • Piston diameter Out of specification → Replace the piston.

5470

Standard

Distance a

Piston diameter

13 mm (0.51 in)

78.928 - 78.949 mm (3.1074 - 3.1082 in)

Oversize piston diameter Oversize 1: + 0.25 mm (0.001 in)

5-38

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

CALCULATING THE PISTON-TOCYLINDER CLEARANCE

Calculate: • Piston-to-cylinder clearance Out of specification → Replace the piston and piston rings, the cylinder block or both. Piston-tocylinder clearance

Cylinder bore

–

Piston diameter

Piston-to-cylinder clearance 0.070 - 0.080 mm (0.0028 - 0.0031 in)

CHECKING THE PISTON RING

1. Measure: • End gap a Out of specification → Replace the piston rings as a set. End gap (installed) Top ring 0.15 - 0.30 mm (0.006 - 0.012 in) 2nd ring 0.70 - 0.90 mm (0.028 - 0.035 in) Oil ring 0.20 - 0.70 mm (0.008 - 0.028 in)

5480

NOTE: Push the piston ring into the cylinder with the piston crown.

5-39

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

2. Measure: • Side clearance a Out of specification → Replace the piston and piston rings as a set. Side clearance Top ring 0.04 - 0.08 mm (0.002 - 0.003 in) 2nd ring 0.03 - 0.07 mm (0.001 - 0.003 in) Oil ring 0.03 - 0.15 mm (0.001 - 0.006 in)

5490

CHECKING THE CRANKSHAFT

Measure: • Crankshaft journal diameter • Crank pin diameter • Crankshaft runout Out of specification → Replace the crankshaft. Crankshaft journal diameter limit 47.972 mm (1.8887 in) Crankshaft runout limit 0.03 mm (0.001 in)

5500

CHECKING THE MAIN-BEARING OIL CLEARANCE

1. Measure: • Main-bearing oil clearance Out of specification → Replace the upper and lower bearings as a set. Main-bearing oil clearance 0.024 - 0.044 mm (0.0009 - 0.0017 in) NOTE: Measure the main-bearing oil clearance at room temperature (20 ˚C (68 ˚F)).

5-40

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

POWR

Measuring steps 3

CAUTION: Install the bearings in their original positions. Incorrect oil clearance measurements can lead to engine damage.

(1) Clean the bearings, main journals, and bearing portions of the crankcase and cylinder block. (2) Place the cylinder block upside down on a bench. (3) Install half of the bearings 1 and the crankshaft 2 into the cylinder block 3. (4) Put a piece of Plastigauge on each main journal in parallel to the crankshaft.

5510

NOTE: Do not put the Plastigauge over the oil hole in the main journal of the crankshaft.

5520

5 E

(5) Install the other half of the bearings into the crankcase. (6) Install the crankcase onto the cylinder block. (7) Apply engine oil on to the threads and seat of the crankcase bolts. (8) Tighten the bolts to the specified torque in two steps in the order shown in the illustration.

K 1

2 L

NOTE: Do not move the crankshaft until the mainbearing oil clearance measurement has been completed.

4 G

H 7

5530

Bolt (M8) 1st: 14 Nm (1.4 m • kgf, 10 ft • lb) 2nd: 28 Nm (2.8 m • kgf, 20 ft • lb) Bolt (M10) 1st: 19 Nm (1.9 m • kgf, 14 ft • lb) 2nd: 60˚ 50 Nm (5.0 m • kgf, 36 ft • lb)*

(9) Remove the crankcase. (10) Measure the width of the compressed Plastigauge on each main journal. * Torque valve (for reference only) 5540

5-41

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

2. Adjust: • Main-bearing oil clearance NOTE: Adjust the main-bearing oil clearance at room temperature (20˚C (68 ˚F)). Adjusting steps

CAUTION: Remove any oil or dust from the cylinder block and crankcase bearing mounting surfaces. (#1)

NOTE: The cylinder block journal diameters (#1 #5) and the crankshaft journal diameters, (#1 - #5) can be determined by the stamped value as described below. Crankshaft journal diameter = 47.900 + (stamped value/1000) Example: #1 = 92 → 47.992 Cylinder block journal diameter = 54.000 + (stamped value/1000) Example: #1 = 32 → 54.032

(#2)

(#3)

(#4) (#5)

(1) Subtract the crankshaft journal diameters (#1 - #5) from the cylinder block journal diameters (#1 - #5). (2) Select the suitable bearing from the table below according to the calculated values.

5550

#1 #2

Crankshaft bearing selection table (20 ˚C (68 ˚F))

Cylinder block Bearing journal diameters – (cylinder side)/ crankshaft journal thrust bearing diameters (mm)

#4 #5 5560

6.023 - 6.026 6.027 - 6.034 6.035 - 6.042 6.043 - 6.049 6.050 - 6.058

5570

5-42

Green Blue Blue Red Red

Bearing (crankcase side) Yellow* Green* Blue Blue* Red

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

CAUTION: The (*) mark indicates that the color of the upper and lower bearings are different. Install the main-bearings in the middle of the cylinder block and crankcase journal so they do not block the oil holes.

NOTE: Crankshaft bearing #3 is a thrust bearing. (3) If the difference between the cylinder block journal diameter and crankshaft journal diameter is more than the maximum value (6.058 mm), replace the crankshaft, cylinder block, or both.

CHECKING THE CONNECTING ROD BIG-END OIL CLEARANCE

CAUTION: • Mark the original connecting rod bolts so they are not confused with the new bolts. • Do not reuse the original connecting rod bolts during assembly, only use them when measuring and adjusting the oil clearance. • Before assembly, remove any small metal particles from the big- end mating surface and also thoroughly clean it. 1. Measure: • Big-end oil clearance Out of specification → Replace the upper and lower bearings as a set. Big-end oil clearance 0.025 - 0.031 mm (0.0010 - 0.0012 in) NOTE: Measure the big-end oil clearance at room temperature (20 ˚C (68 ˚F)).

5-43

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

Measuring steps

CAUTION: Install the bearings in their original positions. Incorrect oil clearance measurements can lead to engine damage. (1) Clean the bearings and bearing portions of the connecting rod. (2) Install the upper half of the bearing into the connecting rod and the lower half into the connecting rod cap. (3) Put a piece of Plastigauge onto the crank pin in parallel to the crankshaft. (4) Assemble the connecting rod onto the crank pin.

5580

a NOTE: • Make sure the projections a and “YAMAHA” mark on the connecting rod faces towards the flywheel side. • Do not move the crankshaft until the bigend oil clearance measurement has been completed.

5590

(5) Apply engine oil onto the threads and seat of the original connecting rod bolts. (6) Tighten the original bolts to the specified torque in two stages.

Bolt 1st: 15 Nm (1.5 m • kgf, 11 ft • lb) 2nd: 60˚

(7) Remove the connecting rod cap. (8) Measure the width of the compressed Plastigauge on each crank pin. 5600

5-44

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

2. Adjust: • Big-end oil clearance NOTE: Adjust the big-end oil clearance at room temperature (20 ˚C (68 ˚F)).

Adjusting steps

CAUTION: Remove any oil or dust from the connecting-rod-bearing mounting surfaces. (1) Install the connecting rod cap to the connecting rod. (2) Tighten the original bolts to the specified torque in two stages.

Bolt: 1st: 15 Nm (1.5 m • kg, 11 ft • lb) 2nd: 60˚

(3) Measure the connecting rod big end diameter a. (4) The crank pin diameters (#1 ~ #4) can be determined by the stamped value as described below. (#1)

NOTE: Crank pin diameter = 41.900 + (stamped value/1,000) Example: #1 = 92 → 41.992

(#2)

(#3)

(5) Subtract the crank pin diameters (#1 ~ #4) from the connecting rod big end diameters (#1 ~ #4). (6) Select the suitable bearing from the table below according to the calculated values.

(#4)

5-45

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY

POWR

Connecting rod bearing selection table (20 ˚C (68 ˚F)) Connecting rod big end diameters – Upper bearing Lower bearing crank pin diameters (mm) 3.025 ~ 3.031 3.032 ~ 3.039 3.040 ~ 3.046 3.047 ~ 3.052 3.053 ~ 3.058 3.059 ~ 3.063

Yellow Yellow Green Green Blue Blue

Yellow Green* Green Blue* Blue Red*

CAUTION: The (*) mark indicates that the color of the upper and lower bearings are different. (7) If the measurement value is more than the maximum value (3.063 mm), replace the crankshaft, connecting rod, or both.

45˚

INSTALLING THE PISTON RING

CAUTION: • Do not scratch the piston or break the piston rings. • After installing the piston rings, check that they move smoothly.

#4 #1

#2 #1 5610

Install: • Oil ring (#3 and #4) • 2nd ring (#2) • Top ring (#1) NOTE: • Offset the piston-ring end gaps as shown. • Piston rings should be replaced as a set.

5-46

POWR

CRANKSHAFT AND PISTON/ CONNECTING ROD ASSEMBLY INSTALLING THE PISTON

E 5

CAUTION: Install the piston with the “UP” mark on the piston crown facing towards the flywheel side. Install: • Piston

5620

Piston ring compressor YU-33294 / 90890-06530

5-47

LOWR

CHAPTER 6 LOWER UNIT LOWER UNIT (REGULAR ROTATION MODELS) ......................................... 6-1 REMOVING/INSTALLING THE LOWER UNIT ........................................ 6-1 REMOVING THE PROPELLER ................................................................. 6-3 CHECKING THE PROPELLER................................................................... 6-3 INSTALLING THE PROPELLER................................................................ 6-3 WATER PUMP (REGULAR ROTATION MODELS)........................................ 6-4 REMOVING/INSTALLING THE WATER PUMP....................................... 6-4 CHECKING THE IMPELLER HOUSING ................................................... 6-6 CHECKING THE IMPELLER AND IMPELLER HOUSING CUP................ 6-6 CHECKING THE WOODRUFF KEY .......................................................... 6-6 INSTALLING THE IMPELLER AND IMPELLER HOUSING ..................... 6-6 SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) ........................ 6-7 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ....................... 6-7 REMOVING THE SHIFT ROD ASSEMBLY .............................................. 6-8

LOWR PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS) ................................................................ 6-9 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.............................................................................................. 6-9 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING .............................................................................................. 6-11 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY............................................................................................ 6-12 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-13 DISASSEMBLING THE PROPELLER SHAFT HOUSING ...................... 6-13 CHECKING THE REVERSE GEAR.......................................................... 6-14 CHECKING THE BEARING..................................................................... 6-14 CHECKING THE PROPELLER SHAFT HOUSING.................................. 6-14 CHECKING THE DOG CLUTCH ............................................................. 6-15 CHECKING THE PROPELLER SHAFT.................................................... 6-15 ASSEMBLING THE PROPELLER SHAFT HOUSING ............................ 6-15 ASSEMBLING THE REVERSE GEAR .................................................... 6-15 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-16 DRIVE SHAFT (REGULAR ROTATION MODELS)....................................... 6-17 REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-17 REMOVING THE DRIVE SHAFT ............................................................ 6-19 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-19 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-19 CHECKING THE PINION ........................................................................ 6-20 CHECKING THE DRIVE SHAFT.............................................................. 6-20 CHECKING THE DRIVE SHAFT HOUSING ........................................... 6-20 CHECKING THE BEARINGS .................................................................. 6-20 ASSEMBLING THE FORWARD GEAR ASSEMBLY ............................. 6-20 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-21 INSTALLING THE DRIVE SHAFT........................................................... 6-22

1 2 3 4 5 6 7 8 9

LOWR LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS).................. 6-23 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-23 DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-24 CHECKING THE DRIVE SHAFT SLEEVE ............................................... 6-24 CHECKING THE NEEDLE BEARING...................................................... 6-24 ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-24 LOWER UNIT (COUNTER ROTATION MODELS) ....................................... 6-26 REMOVING/INSTALLING THE LOWER UNIT ...................................... 6-26 REMOVING THE PROPELLER ............................................................... 6-28 CHECKING THE PROPELLER................................................................. 6-28 INSTALLING THE PROPELLER.............................................................. 6-28 WATER PUMP (COUNTER ROTATION MODELS) ..................................... 6-29 REMOVING/INSTALLING THE WATER PUMP..................................... 6-29 CHECKING THE IMPELLER HOUSING ................................................. 6-31 CHECKING THE IMPELLER AND IMPELLER HOUSING CUP.............. 6-31 CHECKING THE WOODRUFF KEY ........................................................ 6-31 INSTALLING THE IMPELLER AND IMPELLER HOUSING ................... 6-31 SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) ...................... 6-32 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 6-32 REMOVING THE SHIFT ROD ASSEMBLY ............................................ 6-33

LOWR PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS) .............................................................. 6-34 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY............................................................................................ 6-34 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......................................................................... 6-36 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY ............................................................................... 6-38 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-39 REMOVING THE PROPELLER SHAFT ASSEMBLY.............................. 6-39 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY............................................................................................ 6-40 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-40 CHECKING THE FORWARD GEAR........................................................ 6-41 CHECKING THE BEARING..................................................................... 6-41 CHECKING THE PROPELLER SHAFT HOUSING.................................. 6-41 CHECKING THE DOG CLUTCH ............................................................. 6-41 CHECKING THE PROPELLER SHAFT.................................................... 6-41 ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ....... 6-42 INSTALLING THE PROPELLER SHAFT ASSEMBLY ............................ 6-43 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-44

LOWR DRIVE SHAFT (COUNTER ROTATION MODELS) ...................................... 6-45 REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-45 REMOVING THE DRIVE SHAFT ............................................................ 6-47 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-47 DISASSEMBLING THE REVERSE GEAR .............................................. 6-47 CHECKING THE PINION ........................................................................ 6-47 CHECKING THE DRIVE SHAFT.............................................................. 6-47 CHECKING THE DRIVE SHAFT HOUSING ........................................... 6-48 CHECKING THE BEARINGS .................................................................. 6-48 ASSEMBLING THE REVERSE GEAR ASSEMBLY................................ 6-48 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-48 INSTALLING THE DRIVE SHAFT........................................................... 6-49 LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) ................. 6-50 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY .... 6-50 DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-51 CHECKING THE DRIVE SHAFT SLEEVE ............................................... 6-51 CHECKING THE NEEDLE BEARING...................................................... 6-51 ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-52 SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) .......................................................................... 6-53 SELECTING THE PINION SHIMS .......................................................... 6-54 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-56 SELECTING THE REVERSE GEAR SHIMS............................................ 6-58 SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) ........ 6-60 SELECTING THE PINION SHIMS .......................................................... 6-61 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-63 SELECTING THE REVERSE GEAR SHIM .............................................. 6-64

LOWR BACKLASH (REGULAR ROTATION MODELS) ........................................... 6-66 MEASURING THE FORWARD GEAR BACKLASH ............................... 6-66 MEASURING THE REVERSE GEAR BACKLASH.................................. 6-67 SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA) .......................................................................... 6-70 SELECTING THE PINION SHIMS .......................................................... 6-71 SELECTING THE REVERSE GEAR SHIMS............................................ 6-73 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-74 SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-76 SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE) ........ 6-77 SELECTING THE PINION SHIMS .......................................................... 6-78 SELECTING THE REVERSE GEAR SHIMS............................................ 6-80 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-81 SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-83 BACKLASH (COUNTER ROTATION MODELS) .......................................... 6-84 MEASURING THE FORWARD GEAR BACKLASH ............................... 6-84 MEASURING THE REVERSE GEAR BACKLASH.................................. 6-85

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE LOWER UNIT

8 43 Nm (4.3 m • kgf, 31 ft • Ib) 10 × 45 mm : 12 mm

13 55 Nm (5.5 m • kgf, 40 ft • Ib)

7 4

6 A

572

12 37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 45 mm

Order 1 2 3 4 5 6 7

Job/Part Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer

572

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 70 mm

Q’ty 1 1 1 1 1 1 1

6010

Remarks

Continued on next page.

6-1

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

E 6

8 43 Nm (4.3 m • kgf, 31 ft • Ib) 10 × 45 mm : 12 mm

13 55 Nm (5.5 m • kgf, 40 ft • Ib)

7 4

6 A

572

12 37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 45 mm

Order 8 9 10 11 12 13 14

Job/Part Grommet Bolt Trim tab Bolt Bolt Dowel pin Lower unit

572

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 70 mm

Q’ty 1 1 1 1 6 2 1

Remarks

(with washer) (with washer)

For installation, reverse the removal procedure.

6-2

6010

LOWR

LOWER UNIT (REGULAR ROTATION MODELS) REMOVING THE PROPELLER

E 6

Remove: • Propeller

WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop lanyard switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

6020

CHECKING THE PROPELLER

Check: • Blades • Splines Cracks/damage/wear → Replace.

INSTALLING THE PROPELLER

Install: • Propeller

6030

NOTE: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned.

6-3

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE WATER PUMP

18 Nm (1.8 m • kgf, 13 ft • Ib) 8 × 45 mm

6 7 2

572 572

4 3

GM 4

5 8 9 10

11 12

14 15

6040

Order

Job/Part

Q’ty

Lower unit 1 2 3 4 5 6 7 8

Bolt Impeller housing Impeller housing cup O-ring O-ring Grommet Spacer Collar

Remarks Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1.

4 1 1 1 1 1 1 1 Continued on next page.

6-4

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

E 6

18 Nm (1.8 m • kgf, 13 ft • Ib) 8 × 45 mm

6 7 2

572 572

4 3

GM 4

5 8 9 10

11 12

14 15

6040

Order 9 10 11 12 13 14 15 16

Job/Part Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Dowel pin

Q’ty 1 2 1 1 1 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

6-5

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

CHECKING THE IMPELLER HOUSING

Check: • Impeller housing Cracks/damage → Replace.

CHECKING THE IMPELLER AND IMPELLER HOUSING CUP

Check: • Impeller • Impeller housing cup Cracks/damage → Replace any defective parts.

CHECKING THE WOODRUFF KEY

Check: • Woodruff key Damage/wear → Replace.

INSTALLING THE IMPELLER AND IMPELLER HOUSING

1. Install: • Washers 1 • Wave washer 2 • Spacer 3 • Collar 4 NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with some appropriate tool a that fits over the drive shaft as shown.

6050

2. Install: • O-ring 1 • Impeller housing cup 2 • Impeller housing 3 • O-ring 4 NOTE: • When installing the impeller housing cup, align its projection with the hole in the impeller housing. • When installing the water pump housing, turn the drive shaft clockwise. 6060

6-6

LOWR

SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY

1 4 8 Nm (0.8 m • kgf, 5.8 ft • Ib) 6 × 20 mm

3 5

6 8 7

6070

Order

1 2 3 4 5 6 7 8

Job/Part Impeller plate Bolt Shift rod assembly Oil seal housing Oil seal O-ring Spring Shift rod Circlip

Q’ty

3 1 1 1 1 1 1 1

Remarks Refer to “WATER PUMP (REGULAR ROTATION MODELS)” on page 6-4. (with washer)

For installation, reverse the removal procedure.

6-7

LOWR

SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) REMOVING THE SHIFT ROD ASSEMBLY

Remove: â&#x20AC;¢ Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.

6-8

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6080

Order

Job/Part

Q’ty

Gear oil Shift rod assembly

1 2 3 4

Ring nut Claw washer Propeller shaft housing assembly Straight key

Remarks Refer to “CHECKING THE GEAR OIL LEVEL” on page 3-18. Refer to “SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-7.

1 1 1 1 Continued on next page.

6-9

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

6080

Order 5 6 7 8

Job/Part Reverse gear shim Propeller shaft assembly Washer Propeller shaft housing

Qâ&#x20AC;&#x2122;ty * 1 2 1

Remarks

For installation, reverse the removal procedure. *: As required

6-10

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

E 6

DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING

6090

Order 1 2 3 4 5 6 7

Job/Part O-ring Reverse gear Thrust washer Ball bearing Oil seal Needle bearing Propeller shaft housing

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1

Remarks

For assembly, reverse the disassembly procedure.

6-11

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

LOWR

E 6

DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY

2 3 9 8

4 6100

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Spring Pin Dog clutch Shift rod joint Shift rod joint slider Ball Ball Spring Ball Propeller shaft

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2 2 1 2 1

Remarks

For assembly, reverse the disassembly procedure.

6-12

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY

1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513

6110

3. Remove: • Propeller shaft housing assembly 1

Propeller shaft housing puller . YB-06207 / 90890-06502 Universal puller......................... YB-06117 Guide plate................................ 90890-06501 Center bolt ................................ 90890-06504

2 6120

1 2 3 4

Å For USA and Canada ı For worldwide

6130

DISASSEMBLING THE PROPELLER SHAFT HOUSING

1. Remove: • Reverse gear Slide hammer............................ YB-06096 Bearing separator ..................... 90890-06534 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6140

Å For USA and Canada ı For worldwide 6150

6-13

1 2 3 4 5 6

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

2. Remove: • Ball bearing

Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6160

1 2 3 4 5

Å For USA and Canada ı For worldwide

6170

3. Remove: • Oil seal • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06652 6180

CHECKING THE REVERSE GEAR

Check: • Teeth • Dogs Wear/damage → Replace the reverse gear.

CHECKING THE BEARING

Check: • Bearing Pitting/rumbling → Replace.

CHECKING THE PROPELLER SHAFT HOUSING Check: • Propeller shaft housing Cracks/damage → Replace.

6-14

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

LOWR

CHECKING THE DOG CLUTCH

Check: • Dog clutch Damage/wear → Replace.

CHECKING THE PROPELLER SHAFT

Check: • Propeller shaft Damage/wear → Replace.

ASSEMBLING THE PROPELLER SHAFT HOUSING

1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm (0.974 - 0.994 in) 6190

Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

Å For USA and Canada ı For worldwide 6200

2. Install: • Oil seal 2

Oil seal installation position a 4.75 - 5.25 mm (0.187 - 0.207 in)

Bearing/oil seal attachment .... 1 YB-06195 Driver rod .................................. 2 YB-06071

6210

ASSEMBLING THE REVERSE GEAR Install: • Ball bearing Bearing/oil seal attachment YB-06200 / 90890-06661

6220

6-15

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

Install: • Propeller shaft housing assembly • Claw washer • Ring nut Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513

6230

NOTE: To secure the ring nut, bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.

6-16

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE DRIVE SHAFT

6240

Order

1 2 3 4 5 6 7

Job/Part Propeller shaft housing assembly

Nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing Drive shaft

Q’ty

1 1 4 1 * 1 1

Remarks Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-9.

(with washer)

Continued on next page. *: As required

6-17

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

E 6

6240

Order 8 9 10 11 12 13 14 15 16

Job/Part Forward gear assembly O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Tapered roller bearing Needle bearing Forward gear

Qâ&#x20AC;&#x2122;ty 1 1 1 2 1 1 1 1 1

Remarks

Not reusable Not reusable For installation, reverse the removal procedure.

6-18

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

REMOVING THE DRIVE SHAFT

Loosen: • Pinion nut Drive shaft holder ..................... 1 YB-06151 / 90890-06519 Pinion nut holder ...................... 2 90890-06505 Pinion nut holder attachment . 3 90890-06507

6250

DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06652 6260

DISASSEMBLING THE FORWARD GEAR ASSEMBLY

1. Remove: • Tapered roller bearing Bearing separator YB-06219 / 90890-06534 6270

CAUTION: Do not reuse the bearing, always replace it with a new one. 2. Remove: • Needle bearing Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6280

6-19

1 2 3 4 5

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

CHECKING THE PINION

Check: • Teeth Damage/wear → Replace.

CHECKING THE DRIVE SHAFT

Check: • Drive shaft Damage/wear → Replace.

CHECKING THE DRIVE SHAFT HOUSING

Check: • Drive shaft housing Cracks/damage → Replace.

CHECKING THE BEARINGS

Check: • Bearings Pitting/rumbling → Replace.

ASSEMBLING THE FORWARD GEAR ASSEMBLY 1. Install: • Needle bearing Needle bearing installation position a 2.5 - 3.5 mm (0.098 - 0.138 in) 6290

Bearing/oil seal attachment .... 1 YB-06200 / 90890-06612 Driver rod .................................. 2 YB-06071 / 90890-06604

6-20

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

2. Install: • Tapered roller bearing Bearing/oil seal attachment YB-06200 / 90890-06661

6300

ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

1. Install: • Needle bearing Position a 5.75 - 6.25 mm (0.226 - 0.246 in) Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

6310

Å For USA and Canada ı For worldwide

6320

2. Install: • Oil seal Oil seal installation position a 0.25 - 0.75 mm (0.010 - 0.030 in) Bearing/oil seal attachment .... 1 YB-06195 / 90890-06633 Driver rod .................................. 2 YB-06071 / 90890-06652

6330

6-21

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

INSTALLING THE DRIVE SHAFT Tighten: • Pinion nut Drive shaft holder ..................... 1 YB-06151 / 90890-06519 Pinion nut holder ...................... 2 90890-06505 Pinion nut holder attachment . 3 90890-06507

6340

6-22

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY

6350

Order

1 2 3 4 5 6

Job/Part Forward gear Drive shaft sleeve Needle bearing Tapered roller bearing outer race Forward gear shim Water seal Plate

Q’ty

Remarks Refer to “DRIVE SHAFT (REGULAR ROTATION MODELS)” on page 6-17.

1 1 1 * 1 1 For assembly, reverse the disassembly procedure.

*: As required

6-23

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

DISASSEMBLING THE LOWER CASE ASSEMBLY

1. Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06194 / 90890-06636 Driver rod .................................. 2 YB-06071 / 90890-06605 6360

2. Remove: • Tapered roller bearing outer race Slide hammer............................ 1 YB-06096 Bearing puller............................ 2 90890-06523 Large universal claws............... 3 90890-06532 6370

CHECKING THE DRIVE SHAFT SLEEVE

Check: • Drive shaft sleeve Damage/wear → Replace.

CHECKING THE NEEDLE BEARING

Check: • Needle bearing Pitting/rumbling → Replace.

ASSEMBLING THE LOWER CASE ASSEMBLY 1. Install: • Tapered roller bearing outer race Bearing/oil seal attachment .... 1 YB-06199 / 90890-06620 Driver rod .................................. 2 YB-06071 / 90890-06605 6380

6-24

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

2. Install: • Needle bearing

Needle bearing installation position a 168 ± 0.25 mm (6.61 ± 0.01 in) Needle bearing installation position b 184.0 mm (7.24 in) 6390

Bearing/oil seal attachment .... 1 YB-06194 / 90890-06636 Driver rod .................................. 2 YB-06071 / 90890-06602 Bearing/oil seal depth plate .... 3 YB-06213 / 90890-06603 YB-34474

Å For USA and Canada ı For worldwide 6400

6-25

LOWR

LOWER UNIT (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE LOWER UNIT

43 Nm (4.3 m • kgf, 31 ft • Ib) 10 × 45 mm : 12 mm

8 9

55 Nm (5.5 m • kgf, 40 ft • Ib)

13 2 M

7 3 4 5 14

572

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 45 mm

Order 1 2 3 4 5 6 7

Job/Part Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer

11 LT

572

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 70 mm

Q’ty 1 1 1 1 1 1 1

6410

Remarks

Continued on next page.

6-26

LOWR

LOWER UNIT (COUNTER ROTATION MODELS)

E 6

43 Nm (4.3 m • kgf, 31 ft • Ib) 10 × 45 mm : 12 mm

8 9

55 Nm (5.5 m • kgf, 40 ft • Ib)

13 2 M

7 3 4 5 14

572

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 45 mm

Order 8 9 10 11 12 13 14

Job/Part Grommet Bolt Trim tab Bolt Bolt Dowel pin Lower unit

37 Nm (3.7 m • kgf, 27 ft • Ib) 10 × 70 mm

Q’ty 1 1 1 1 6 2 1

6410

Remarks

(with washer) (with washer)

For installation, reverse the removal procedure.

6-27

LOWR

LOWER UNIT (COUNTER ROTATION MODELS) REMOVING THE PROPELLER

E 6

Remove: • Propeller

6420

CHECKING THE PROPELLER

Check: • Blades • Splines Cracks/damage/wear → Replace.

INSTALLING THE PROPELLER

Install: • Propeller

6430

NOTE: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned.

6-28

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE WATER PUMP

18 Nm (1.8 m • kgf, 13 ft • Ib) 8 × 45 mm

6 7 2

572 572

4 3

GM 4

5 8 9 10

11 12

14 15

6040

Order

Job/Part

Q’ty

Lower unit 1 2 3 4 5 6 7 8

Bolt Impeller housing Impeller housing cup O-ring O-ring Grommet Spacer Collar

Remarks Refer to “LOWER UNIT (COUNTER ROTATION MODELS)” on page 6-26.

4 1 1 1 1 1 1 1 Continued on next page.

6-29

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

E 6

18 Nm (1.8 m • kgf, 13 ft • Ib) 8 × 45 mm

6 7 2

572 572

4 3

GM 4

5 8 9 10

11 12

14 15

6040

Order 9 10 11 12 13 14 15 16

Job/Part Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Dowel pin

Q’ty 1 2 1 1 1 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

6-30

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

CHECKING THE IMPELLER HOUSING

Check: • Impeller housing Cracks/damage → Replace.

CHECKING THE IMPELLER AND IMPELLER HOUSING CUP

Check: • Impeller • Impeller housing cup Cracks/damage → Replace any defective parts.

CHECKING THE WOODRUFF KEY

Check: • Woodruff key Damage/wear → Replace.

INSTALLING THE IMPELLER AND IMPELLER HOUSING

6050

6-31

LOWR

SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY

6450

Order

1 2 3 4 5 6 7 8

Job/Part Impeller plate Bolt Shift rod assembly Oil seal housing Oil seal O-ring Spring Shift rod Circlip

Q’ty

3 1 1 1 1 1 1 1

Remarks Refer to “WATER PUMP (COUNTER ROTATION MODELS)” on page 6-29. (with washer)

3.1 × 49.4 mm

For installation, reverse the removal procedure.

6-32

LOWR

SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS) REMOVING THE SHIFT ROD ASSEMBLY

Remove: â&#x20AC;¢ Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.

6-33

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6460

Order

Job/Part

Q’ty

Gear oil Shift rod assembly

1 2 3

Ring nut Claw washer Propeller shaft housing assembly

Remarks Refer to “CHANGING AND CHECKING THE GEAR OIL” on page 3-18. Refer to “SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)” on page 6-32.

1 1 1 Continued on next page.

6-34

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

E 6

6460

Order Job/Part 4 Straight key 5 Thrust washer 6 Forward gear shim

Qâ&#x20AC;&#x2122;ty 1 1 *

Remarks

For installation, reverse the removal procedure. *: As required

6-35

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

E 6

DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6470

Order 1 2 3 4 5 6 7 8

Job/Part O-ring Spring Pin Dog clutch Forward gear assembly Propeller shaft assembly Thrust bearing Propeller shaft shim

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 *

Remarks

Continued on next page. *: As required

6-36

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

E 6

6470

Order 9 10 11 12 13 14 15

Job/Part Oil seal Needle bearing Propeller shaft housing Forward gear Thrust washer Tapered roller bearing outer race Tapered roller bearing

Qâ&#x20AC;&#x2122;ty 2 1 1 1 1 1 1

6-37

Remarks

Not reusable For assembly, reverse the disassembly procedure.

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

E 6

DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY

6480

Order 1 2 3 4 5 6

Job/Part Shift rod joint Shift rod joint slider Ball Spring Ball Propeller shaft

Qâ&#x20AC;&#x2122;ty 1 1 4 1 2 1

Remarks

For assembly, reverse the disassembly procedure.

6-38

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY

1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513

6110

3. Remove: • Propeller shaft housing assembly • Straight key • Forward gear shim(s)

Slide hammer attachment....... 1 YB-06335 / 90890-06514 Slide hammer............................ 2 YB-06096 / 90890-06531

REMOVING THE PROPELLER SHAFT ASSEMBLY Remove: • Propeller shaft assembly • Forward gear assembly Propeller shaft housing puller . YB-06207 / 90890-06502 Universal puller......................... YB-06117 Guide plate................................ 90890-06501 Center bolt ................................ 90890-06504

6500

6-39

1 2 2 3

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

Remove: • Oil seals • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06652

6510

DISASSEMBLING THE FORWARD GEAR ASSEMBLY

Remove: • Tapered roller bearing Bearing separator YB-06219 / 90890-06534 6540

CAUTION: Do not reuse the bearing, always replace it with a new one.

6-40

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

CHECKING THE FORWARD GEAR

Check: • Teeth • Dogs Damage/wear → Replace.

CHECKING THE BEARING

Check: • Bearing Pitting/rumbling → Replace.

CHECKING THE PROPELLER SHAFT HOUSING

Check: • Propeller shaft housing Cracks/damage → Replace.

CHECKING THE DOG CLUTCH

Check: • Dog clutch Damage/wear → Replace.

CHECKING THE PROPELLER SHAFT Check: • Propeller shaft Damage/wear → Replace.

6-41

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm (0.974 - 0.994 in) 6590

Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

Å For USA and Canada ı For worldwide 6600

2. Install: • Needle bearing 3. Install: • Oil seal

Oil seal installation position a 4.75 - 5.25 mm (0.187 - 0.207 in) Bearing/oil seal attachment YB-06195 / 90890-06640

6590

Å For USA and Canada ı For worldwide

6600

6-42

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

INSTALLING THE PROPELLER SHAFT ASSEMBLY Install: • Forward gear assembly • Propeller shaft assembly Ring nut wrench YB-06578 / 90890-06578 6600

6-43

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

Install: • Forward gear shim(s) • Propeller shaft housing assembly • Straight key • Claw washer • Ring nut 6230

Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513 NOTE: To secure the ring nut, bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.

6-44

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE DRIVE SHAFT

6650

Order

1 2 3 4 5 6 7

Job/Part Propeller shaft housing assembly

Nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing Drive shaft

Q’ty

1 1 4 1 * 1 1

Remarks Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)” on page 6-34.

(with washer)

Continued on next page. *: As required

6-45

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

E 6

6650

Order 8 9 10 11 12 13 14 15 16

Job/Part Reverse gear assembly Thrust bearing O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Needle bearing Reverse gear

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1 1 1

Remarks

For installation, reverse the removal procedure.

6-46

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

REMOVING THE DRIVE SHAFT

Loosen: • Pinion nut Drive shaft holder ..................... 1 YB-06151 / 90890-06519 Pinion nut holder ...................... 2 90890-06505 Pinion nut holder attachment . 3 90890-06507

6250

DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06652 6260

DISASSEMBLING THE REVERSE GEAR

Remove: • Needle bearing Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6660

CHECKING THE PINION

1 2 3 4 5

Check: • Teeth Damage/wear → Replace.

CHECKING THE DRIVE SHAFT Check: • Drive shaft Damage/wear → Replace. 6-47

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

CHECKING THE DRIVE SHAFT HOUSING

Check: • Drive shaft housing Cracks/damage → Replace.

CHECKING THE BEARINGS

Check: • Bearings Pitting/rumbling → Replace.

ASSEMBLING THE REVERSE GEAR ASSEMBLY

Install: • Needle bearing Needle bearing installation position a 2.5 - 3.5 mm (0.098 - 0.138 in)

6290

Bearing/oil seal attachment .... 1 YB-06200 / 90890-06612 Driver rod .................................. 2 YB-06071 / 90890-06604

ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

6310

Å For USA and Canada ı For worldwide

6320

6-48

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

2. Install: • Oil seal Oil seal installation position a 0.25 - 0.75 mm (0.010 - 0.030 in) Bearing/oil seal attachment .... 1 YB-06195 Driver rod .................................. 2 YB-06071

6330

6340

6-49

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY

6 7

4 3

7 Nm (0.7 m • kgf, 5.1 ft • Ib)

6670

Order

1 2 3 4 5 6 7

Job/Part Reverse gear Drive shaft sleeve Needle bearing Bearing retainer Needle bearing Reverse gear shim Water seal Plate

5 Nm (0.5 m • kgf, 3.7 ft • Ib)

Q’ty

Remarks Refer to “DRIVE SHAFT (COUNTER ROTATION MODELS)” on page 6-45.

1 1 1 1 * 1 1 For assembly, reverse the disassembly procedure.

*: As required

6-50

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

DISASSEMBLING THE LOWER CASE ASSEMBLY

1. Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06194 / 90890-06636 Driver rod .................................. 2 YB-06071 / 90890-06605 6360

2. Remove: • Roller bearing Slide hammer............................ 1 YB-06096 Bearing puller............................ 2 90890-06523 Large universal claws............... 3 90890-06532 6680

3. Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06376 / 90890-06607 Driver rod .................................. 2 YB-06071 / 90890-06652

6690

CHECKING THE DRIVE SHAFT SLEEVE

Check: • Drive shaft sleeve Damage/wear → Replace.

CHECKING THE NEEDLE BEARING Check: • Needle bearing Pitting/rumbling → Replace.

6-51

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

ASSEMBLING THE LOWER CASE ASSEMBLY 1. Install: • Needle bearing Needle bearing installation position a 0.75 - 1.25 mm (0.030 - 0.049 in) 6700

Bearing/oil seal attachment .... 1 YB-06376 / 90890-06607 Driver rod .................................. 2 YB-06071 / 90890-06652

2. Install: • Bearing retainer Bearing/oil seal attachment .... 1 YB-06377 / 90890-06630 Driver rod .................................. 2 YB-06071 / 90890-06605

6710

3. Install: • Needle bearing

6720

Needle bearing installation position a 184.0 mm (7.24 in) Bearing/oil seal attachment .... 1 YB-06194 / 90890-06636 Driver rod .................................. 2 YB-06071 / 90890-06602 Bearing/oil seal depth plate .... 3 YB-34474 / 90890-06603

6-52

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reassembling with the original inner parts and a new case (the difference between the original inner parts and the new case). • Measurements and adjustments are required when replacing the inner part(s).

B3 T3

A3 B4

59.0

F R

T1 B1 34.0 A2 T2 A1

B2 15.8

6730

6-53

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

LOWR

SELECTING THE PINION SHIMS

NOTE: Find the shim thickness (T3) by selecting shims until the specified value (M0) is obtained with the special tool.

6740

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.00 + P/100 mm Measuring steps (1) Calculate the specified value (M0).

6750

F+5 P+2 R-1

NOTE: “P” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “P” mark is missing or unreadable, assume a “P” value of “0”, and check the backlash when the unit is assembled. 6760

Example: If “P” is “+5”, then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is “–3”, then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm

6-54

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

LOWR

(2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2. Pinion height gauge YB-34432-6, -11 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim.

6770

(3) Install the pinion and pinion nut.

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

(4) Measure the specified measurement (M).

NOTE: • Measure the clearance between the pinion height gauge and the lower surface of the pinion as shown. • Perform the same measurement at three points on the pinion. • Find the average of the measurements (M).

6750

2. Adjust: • Shim thickness (T3) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-55

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE FORWARD GEAR SHIMS

NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6780

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. Specified value (M0) = 1.80 + F/100 mm Measuring steps (1) Calculate the specified value (M0).

6790

F+5 P+2 R-1

NOTE: “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled. 6800

Example: If “F” is “+5”, then M0 = 1.80 + (+5)/100 mm = 1.80 + 0.05 mm = 1.85 mm If “F” is “–3”, then M0 = 1.80 + (–3)/100 mm = 1.80 – 0.03 mm = 1.77 mm

6-56

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the shimming gauge, bearing 1, and shim(s) 2. Shimming gauge YB-34446-1, -3, -5, -7 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M).

6810

2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-57

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE REVERSE GEAR SHIMS

NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6820

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.80 – R/100 mm Measuring steps (1) Calculate the specified value (M0).

6830

F+5 P+2 R-1

NOTE: “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume an “R” value of “0”, and check the backlash when the unit is assembled. 6840

Example: If “R” is “+5”, then M0 = 1.80 – (+5)/100 mm = 1.80 – 0.05 mm = 1.75 mm If “R” is “–3”, then M0 = 1.80 – (–3)/100 mm = 1.80 + 0.03 mm = 1.83 mm

6-58

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the shimming gauge, bearing, thrust washer, reverse gear, and shim(s).

Shimming gauge YB-34468-2 NOTE: • If the original shim(s) is unavailable, start with a 0.50-mm shim. • Turn the reverse gear assembly a few times until the gear and bearing are horizontal.

6830

(3) Measure the specified measurement (M). 2. Adjust: • Shim thickness (T2) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-59

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)

B3 T3

A3 B4

59.0

F R

T1 B1 34.0 A2 T2 A1

B2 15.8

6730

6-60

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE) SELECTING THE PINION SHIMS

E 6

NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T3)

6850

Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bearing 2, and washer 3.

6860

(2) Install the pinion and pinion nut.

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

(3) Install the pinion height gauge. Pinion height gauge 90890-06702 NOTE: After the wing nuts contact the fixing plate, tighten them another 1/4 of a turn. (4) Measure (M4). Digital caliper 90890-06704 NOTE: • Measure the clearance between the pinion height gauge and the pinion, as shown. • Perform the same measurement at three points on the pinion. • Find the average of the measurements (M4).

6870

6-61

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)

(5) Calculate the pinion shim thickness (T3).

F+5 P+2 R-1

Pinion shim thickness (T3) = 62.5 + P/100 – M3 – M4 NOTE: “P” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “P” mark is missing or unreadable, assume a “P” value of “0”, and check the backlash when the unit is assembled.

6880

Example: If M3 is “46.85 mm”, M4 is “15.12 mm” and P is “–5”, then T3 = 62.5 + (–5)/100 – 46.85 – 15.12 mm = 62.5 – 0.05 – 46.85 – 15.12 mm = 0.48 mm (6) Select the pinion shim(s) (T3). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-62

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)

SELECTING THE FORWARD GEAR SHIMS

NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T1)

6890

Selecting steps (1) Measure (M1). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704 6900

NOTE: • Turn the roller bearing outer race two or three times so the rollers seat. Then, measure the height of the bearing, as shown. • Perform the same measurement at three points on the roller bearing outer race. • Find the average of the measurements (M1).

(2) Calculate the forward gear shim thickness (T1). Forward gear shim thickness (T1) (T1) = 24.6 + F/100 – M1 NOTE: “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled.

6910

6-63

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)

Example: If M1 is “24.10 mm” and F is “+5”, then T1 = 24.6 + (+5)/100 – 24.10 mm = 24.6 + 0.05 – 24.10 mm = 0.55 mm (3) Select the forward gear shim(s) (T1). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

SELECTING THE REVERSE GEAR SHIM

NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the calculation formula. 6920

Select: • Shim thickness (T2) Selecting steps (1) Measure (M2). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704

6930

NOTE: • Measure the height of the gear as shown. • Perform the same measurement at three points on the gear. • Find the average of the measurements (M2).

6-64

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR WORLDWIDE)

(2) Calculate the reverse gear shim thickness (T2). Reverse gear shim thickness (T2) = M2 – 27.4 – R/100 NOTE: “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume a “R” value of “0”, and check the backlash when the unit is assembled. F+5 P+2 R-1

Example: If M2 is “27.95 mm”, R is “+2”, then T2 = 27.95 – 27.4 – (+2)/100 mm = 27.95 – 27.4 – 0.02 mm = 0.53 mm

6940

(3) Select the reverse gear shim(s) (T2). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.05

0.08

0.10

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-65

LOWR

BACKLASH (REGULAR ROTATION MODELS)

NOTE: • Do not install the water pump components when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear backlashes are larger than specification, the pinion may be too high. • If both the forward and reverse gear backlashes are smaller than specification, the pinion may be too low.

MEASURING THE FORWARD GEAR BACKLASH

1. Measure: • Forward gear backlash Out of specification → Adjust. Forward gear backlash 0.19 - 0.53 mm (0.007 - 0.021 in) Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052 (2) Install the propeller shaft housing puller so it pushes against the propeller shaft. 6950

Propeller shaft housing puller . YB-06207 / 90890-06502 Universal puller......................... YB-06117 / 90890-06521 Guide plate................................ 90890-06501 Center bolt ................................ 90890-06504

6960

6-66

Center bolt 10 Nm (1.0 m • kgf, 7.2 ft • lb)

1 2 3 4

LOWR

BACKLASH (REGULAR ROTATION MODELS)

(3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator .................... 5 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator.

6970

Magnetic base attaching plate ........................................... 6 YB-07003 / 90890-07003 Dial gauge set ........................... 7 YU-03097 / 90890-01252 Magnetic base........................... 8 YU-34481 / 90890-06705 (5) Set the lower unit upside down. (6) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash. 2. Adjust: • Forward gear shim Remove or add shim(s). Forward gear backlash

Shim thickness

Less than To be decreased by 0.19 mm (0.007 in) (0.36 – M) × 0.58 More than To be increased by 0.53 mm (0.021 in) (M – 0.36) × 0.58 M: Measurement

MEASURING THE REVERSE GEAR BACKLASH 1. Measure: • Reverse gear backlash Out of specification → Adjust. Reverse gear backlash 0.86 - 1.26 mm (0.034 - 0.050 in)

6-67

LOWR

BACKLASH (REGULAR ROTATION MODELS)

Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052

6950

(2) Load the reverse gear by installing the propeller without the spacer 1 and then tighten the propeller nut.

Propeller nut 10 Nm (1.0 m â&#x20AC;˘ kgf, 7.2 ft â&#x20AC;˘ lb)

6980

(3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator .................... 1 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator.

6990

Magnetic-base plate................. 2 YB-07003 / 90890-07003 Dial gauge set ........................... 3 YU-03097 / 90890-01252 Magnetic base........................... 4 YU-34481 / 90890-06705 (5) Set the lower unit upside down. (6) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash.

6-68

LOWR

BACKLASH (REGULAR ROTATION MODELS)

2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear backlash Less than 0.86 mm (0.034 in)

To be increased by (1.06 – M) × 0.58

More than 1.26 mm (0.050 in)

To be decreased by (M – 1.06) × 0.58

M: Measurement

6-69

Shim thickness

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

B3 T3

59.0

T1 B1 33.3 A2 T2 A1 B2 15.1

6A10

6-70

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

LOWR

SELECTING THE PINION SHIMS

NOTE: Find the shim thickness (T3) by selecting shims until the specified measurement (M) is obtained with the special tool.

6740

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.00 + P/100 mm Measuring steps (1) Calculate the specified value (M0).

6750

F+5 P+2 R-1

Example: If “P” is “+5”, then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is “–3”, then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm

6-71

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

LOWR

(2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2. Pinion height gauge YB-34432-6, -11 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim.

6770

(3) Install the pinion and pinion nut.

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

(4) Measure the specified measurement (M).

6750

2. Adjust: • Shim thickness (T3) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-72

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE REVERSE GEAR SHIMS

NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6780

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. Specified value (M0) = 25.30 + F/100 mm Measuring steps (1) Calculate the specified value (M0).

6A30

F+5 P+2 R-1

Example: If “F” is “+5”, then M0 = 25.30 + (+5)/100 mm = 25.30 + 0.05 mm = 25.35 mm If “F” is “–3”, then M0 = 25.30 + (–3)/100 mm = 25.30 – 0.03 mm = 25.27 mm

6-73

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the roller bearing 1, thrust bearing 2, and shim(s) 3. NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M).

6A50

2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

SELECTING THE FORWARD GEAR SHIMS

NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6820

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. M

Specified value (M0) = 1.10 – R/100 mm

6A60

6-74

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

Measuring steps (1) Calculate the specified value (M0).

F+5 P+2 R-1

6A70

Example: If “R” is “+5”, then M0 = 1.10 – (+5)/100 mm = 1.10 – 0.05 mm = 1.05 mm If “R” is “–3”, then M0 = 1.10 – (–3)/100 mm = 1.10 + 0.03 mm = 1.13 mm

(2) Install the shimming gauge, bearing, thrust washer, forward gear, and shim(s). M

Shimming gauge YB-34468-2 NOTE: • If the original shim(s) is unavailable, start with a 0.50-mm shim. • Turn the forward gear assembly a few times until the gear and bearing are horizontal.

6A60

(3) Measure the specified measurement (M).

6-75

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

2. Adjust: • Shim thickness (T2) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

SELECTING THE PROPELLER SHAFT SHIMS

NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool.

6A80

1. Install: • Shim(s) 1 • Thrust bearing 2 • Propeller shaft 3 • Tapered roller bearing 4

6A90

2. Measure: • Propeller shaft free play Out of specification → Adjust. Propeller shaft free play 0.30 ± 0.05 mm Magnetic base........................... 1 YU-34481 / 90890-06705 Dial gauge set ........................... 2 YU-03097 / 90890-01252

6B10

3. Adjust: • Propeller shaft free play Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-76

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

B3 T3

59.0

T1 B1 33.3 A2 T2 A1 B2 15.1

6A10

6-77

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE) SELECTING THE PINION SHIMS

E 6

NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T3)

6850

Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bearing 2, and washer 3.

6860

(2) Install the pinion and pinion nut.

Pinion nut 93 Nm (9.3 m • kgf, 67 ft • lb)

6870

6-78

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

(5) Calculate the pinion shim thickness (T3).

F+5 P+2 R-1

6B20

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-79

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

SELECTING THE REVERSE GEAR SHIMS

NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T1)

6890

Selecting steps (1) Measure (M1). Digital caliper 90890-06704 NOTE: • Measure the combined thickness of the roller bearing 1 and thrust bearing 2. • Turn the roller bearing outer race two or three times so the rollers seat. Then, measure the height of the bearing, as shown. • Perform the same measurement at three points on the roller bearing outer race. • Find the average of the measurements (M1). 6B30

(2) Calculate the reverse gear shim thickness (T1).

F+5 P+2 R-1

Reverse gear shim thickness (T1) (T1) = 25.3 + F/100 – M1 NOTE: “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled.

6B40

6-80

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

Example: If M1 is “24.80 mm” and F is “+5”, then T1 = 25.3 + (+5)/100 – 24.80 mm = 25.3 + 0.05 – 24.80 mm = 0.55 mm (3) Select the reverse gear shim(s). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

SELECTING THE FORWARD GEAR SHIMS

NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T2)

6920

Selecting steps (1) Measure (M2). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704 6930

NOTE: • Measure the height of the gear as shown. • Perform the same measurement at three points on the gear. • Find the average of the measurements (M2).

6-81

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

(2) Calculate the forward gear shim thickness (T2).

F+5 P+2 R-1

Forward gear shim thickness (T2) = M2 – 28.1 – R/100 NOTE: “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume a “R” value of “0”, and check the backlash when the unit is assembled.

6B50

Example: If M2 is “29.10 mm”, R is “+2”, then T2 = 29.10 – 28.1 – (+2)/100 mm = 29.10 – 28.1 – 0.02 mm = 0.98 mm (3) Select the forward gear shim(s) (T2). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.05

0.08

0.10

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-82

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR WORLDWIDE)

SELECTING THE PROPELLER SHAFT SHIMS

NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool. 6A80

1. Install: • Shim(s) 1 • Thrust bearing 2 • Propeller shaft 3 • Tapered roller bearing 4

6A90

6B10

3. Adjust: • Propeller shaft free play Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-83

LOWR

BACKLASH (COUNTER ROTATION MODELS)

MEASURING THE FORWARD GEAR BACKLASH

1. Measure: • Forward gear backlash Out of specification → Adjust. Forward gear backlash 0.31 - 0.66 mm (0.012 - 0.026 in) Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052 (2) Install the propeller shaft housing puller so it pushes against the propeller shaft. 6950

6960

6-84

Center bolt 10 Nm (1.0 m • kgf, 7.2 ft • lb)

1 2 3 4

LOWR

BACKLASH (COUNTER ROTATION MODELS)

6970

Shim thickness

Less than 0.31 mm (0.012 in)

To be increased by (0.49 – M) × 0.58

More than 0.66 mm (0.026 in)

To be decreased by (M – 0.49) × 0.58

M: Measurement

MEASURING THE REVERSE GEAR BACKLASH 1. Measure: • Reverse gear backlash Out of specification → Adjust. Reverse gear backlash 0.86 - 1.21 mm (0.034 - 0.048 in)

6-85

LOWR

BACKLASH (COUNTER ROTATION MODELS)

Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052

6950

(2) Install the propeller shaft housing puller so it pushes against the propeller shaft. Propeller shaft housing puller . YB-06207 / 90890-06502 Universal puller......................... YB-06117 Guide plate................................ 90890-06501 Center bolt ................................ 90890-06504

6B60

1 2 3 4

Center bolt 10 Nm (1.0 m â&#x20AC;˘ kgf, 7.2 ft â&#x20AC;˘ lb)

6B60

6-86

LOWR

BACKLASH (COUNTER ROTATION MODELS)

(6) Turn the shift rod into the reverse position with the shift rod wrench. (7) Turn the drive shaft clockwise until the clutch dog is fully engaged.

6B70

(8) Turn the shift rod into the neutral position with the shift rod wrench. (9) Turn the drive shaft counterclockwise approximately 30˚ more.

6B80

(10) Turn the shift rod into the reverse position with the shift rod wrench. (11) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash. NOTE: When measuring the reverse gear backlash, turn the shift rod wrench towards the reverse position with force.

6B90

2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear backlash Less than 0.86 mm (0.034 in)

To be decreased by (1.0 – M) × 0.58

More than 1.21 mm (0.048 in)

To be increased by (M – 1.0) × 0.58

M: Measurement

6-87

Shim thickness

BRKT

CHAPTER 7 BRACKET UNIT STEERING HANDLE (OPTION) ...................................................................... 7-1 REMOVING/INSTALLING THE STEERING FRICTION............................ 7-1 REMOVING/INSTALLING THE STEERING HANDLE ............................. 7-2 DISASSEMBLING/ASSEMBLING THE STEERING HANDLE................. 7-4 DISASSEMBLING/ASSEMBLING THE STEERING HANDLE SUB ASSEMBLY ..................................................................................... 7-7 SHIFT ROD ASSEMBLY ............................................................................... 7-10 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 7-10 BOTTOM COWLING..................................................................................... 7-13 REMOVING/INSTALLING THE BOTTOM COWLING ........................... 7-13 UPPER CASE ASSEMBLY............................................................................ 7-16 REMOVING/INSTALLING THE UPPER CASE ASSEMBLY .................. 7-16 DISASSEMBLING/ASSEMBLING THE OIL PUMP ............................ 7-17-1 DISASSEMBLING THE OIL PUMP ASSEMBLY ................................ 7-17-2 CHECKING THE OIL PUMP ASSEMBLY............................................ 7-17-2 ASSEMBLING THE OIL PUMP ASSEMBLY ...................................... 7-17-2 DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY ..... 7-18 OIL PAN......................................................................................................... 7-21 DISASSEMBLING/ASSEMBLING THE OIL PAN .................................. 7-21 CLAMP BRACKETS ...................................................................................... 7-24 REMOVING/INSTALLING THE CLAMP BRACKETS............................. 7-24 STEERING ARM............................................................................................ 7-26 REMOVING/INSTALLING THE STEERING ARM.................................. 7-26 SWIVEL BRACKET ASSEMBLY................................................................... 7-27 DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY............................................................................................ 7-27 POWER TRIM AND TILT UNIT..................................................................... 7-29 REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT........... 7-29 REMOVING THE POWER TRIM AND TILT UNIT ................................. 7-31 BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-31

BRKT RESERVOIR AND POWER TRIM AND TILT MOTOR ................................. 7-33 REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR................................................................................. 7-33 CHECKING THE RESERVOIR................................................................. 7-34 CHECKING THE GEAR PUMP HOUSING FILTER ................................ 7-34 INSTALLING THE POWER TRIM AND TILT MOTOR........................... 7-35 FILLING THE RESERVOIR...................................................................... 7-36 BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-36 MEASURING THE HYDRAULIC PRESSURE ........................................ 7-38 TILT RAM ASSEMBLY AND GEAR PUMP UNIT ........................................ 7-41 REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT ................................................................................ 7-41 REMOVING THE TILT RAM END SCREW ............................................ 7-43 REMOVING THE GEAR PUMP UNIT .................................................... 7-43 DISASSEMBLING THE GEAR PUMP UNIT .......................................... 7-43 CHECKING THE TILT RAM .................................................................... 7-44 CHECKING THE GEAR PUMP UNIT...................................................... 7-44 ASSEMBLING THE GEAR PUMP UNIT ................................................ 7-45 INSTALLING THE GEAR PUMP UNIT................................................... 7-46 INSTALLING THE TILT RAM ASSEMBLY ............................................ 7-46 TRIM RAM ASSEMBLIES AND FREE PISTON ........................................... 7-48 REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON ........................................................................................ 7-48 REMOVING THE TRIM RAM END SCREWS ........................................ 7-49 REMOVING THE FREE PISTON............................................................. 7-49 CHECKING THE TRIM RAMS ................................................................ 7-50 CHECKING THE FREE PISTON.............................................................. 7-50 CHECKING THE TRIM RAM CYLINDERS ............................................. 7-50 INSTALLING THE FREE PISTON........................................................... 7-50 INSTALLING THE TRIM RAMS ............................................................. 7-51

1 2 3 4 5 6 7 8 9

BRKT

STEERING HANDLE (OPTION)

REMOVING/INSTALLING THE STEERING FRICTION

7010

Order 1 2 3 4 5 6 7

Job/Part Bolt Nut Bolt Washer Collar Nut Nut

Qâ&#x20AC;&#x2122;ty 2 2 2 2 2 2 1

Remarks

Continued to next page.

7-1

BRKT

STEERING HANDLE (OPTION)

E 7

7010

Order 8 9 10 11 12 13

Job/Part Washer Steering lock shaft Steering lock knob Bracket Friction piece Friction plate

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1

Remarks

For installation, reverse the removal procedure.

7-1-1

BRKT

STEERING HANDLE (OPTION)

E 7

REMOVING/INSTALLING THE STEERING HANDLE

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Bolt Fitting plate Clip Throttle cable Bolt Cable clamp Shift cable Bolt Plate Bolt

Qâ&#x20AC;&#x2122;ty 2 1 2 1 1 1 1 1 1 1

Remarks

Continued on next page.

7-2

BRKT

STEERING HANDLE (OPTION)

E 7

Order 11 12 13 14 15 16 17 18

Job/Part Clamp Main switch leads Trailer/PTT switch coupler Extension, wire harness Nut Steering handle assembly Nut Bracket

Qâ&#x20AC;&#x2122;ty 1 5 1 1 2 1 2 1

Remarks

For installation, reverse the removal procedure.

7-3

BRKT

STEERING HANDLE (OPTION)

E 7

DISASSEMBLING/ASSEMBLING THE STEERING HANDLE

6 × 16 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib)

8 × 40 mm 18 Nm (1.8 m • kgf, 13 ft • Ib)

5 × 20 mm 6 × 20 mm 6 × 40 mm

6 × 25 mm 5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm 7030

Order 1 2 3 4 5 6 7 8

Job/Part Engine stop lanyard switch leads Bolt Bolt Nut Screw Cover Main switch assembly Holder

Q’ty 2 1 1 1 1 1 1 1

Remarks

Continued on next page.

7-4

BRKT

STEERING HANDLE (OPTION)

E 7

6 × 16 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib)

8 × 40 mm 18 Nm (1.8 m • kgf, 13 ft • Ib)

5 × 20 mm 6 × 20 mm 6 × 40 mm

6 × 25 mm 5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm 7030

Order 9 10 11 12 13 14 15 16 17

Job/Part Screw Throttle grip Washer Spring Bushing Screw Screw Cover Screw

Q’ty 1 1 1 1 1 5 2 1 2

Remarks

Continued on next page.

7-5

BRKT

STEERING HANDLE (OPTION)

E 7

6 × 16 mm 4 Nm (0.4 m • kgf, 2.9 ft • Ib)

8 × 40 mm 18 Nm (1.8 m • kgf, 13 ft • Ib)

5 × 20 mm 6 × 20 mm 6 × 40 mm

6 × 25 mm 5 Nm (0.5 m • kgf, 3.7 ft • Ib)

6 × 16 mm 7030

Order 18 19 20 21 22 23 24 25 26

Job/Part Power trim and tilt switch Nut Engine stop lanyard switch Screw Shift lever cover Bolt Shift lever Bushing Steering handle sub assembly

Q’ty 1 1 1 2 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-6

BRKT

STEERING HANDLE (OPTION)

E 7

DISASSEMBLING/ASSEMBLING THE STEERING HANDLE SUB ASSEMBLY

38 Nm (3.8 m • kgf, 27.5 ft • Ib)

6 × 14 mm

6 × 14 mm 10 × 80 mm

6 × 30 mm 7040

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part Clip Cable clamp Throttle cable (short) Bolt Shift cable bracket Cotter pin Friction adjusting knob Bolt Bolt Throttle shaft Friction piece

Q’ty 1 1 1 1 1 1 1 1 2 1 1

Remarks

Continued on next page.

7-7

BRKT

STEERING HANDLE (OPTION)

E 7

38 Nm (3.8 m • kgf, 27.5 ft • Ib)

6 × 14 mm

6 × 14 mm 10 × 80 mm

6 × 30 mm 7040

Order 12 13 14 15 16 17 18 19 20 21 22

Job/Part Frame Clip Shift cable (long) Throttle arm shaft Throttle arm Screw Spring housing Roller Actuator Spring Shift arm

Q’ty 1 1 1 1 1 2 1 1 1 1 1

Remarks

Continued on next page.

7-8

BRKT

STEERING HANDLE (OPTION)

E 7

38 Nm (3.8 m • kgf, 27.5 ft • Ib)

6 × 14 mm

6 × 14 mm 10 × 80 mm

6 × 30 mm 7040

Order 23 24 25 26 27 28 29 30 31 32 33

Job/Part Bushing Nut Washer Bolt Washer Wave washer Collar Bracket Washer Bushing Steering handle

Q’ty 1 1 1 1 1 1 1 1 1 2 1

Remarks

For assembly, reverse the disassembly procedure. 7-9

BRKT

SHIFT ROD ASSEMBLY

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY 12 18 Nm (1.8 m • kgf, 13 ft • Ib)

13 14 15

16 20

4 × 16 mm

6 × 25 mm

6 × 40 mm

4 5 21 17

3 A

6 × 12 mm

7 A

11 9

Order 1 2 3 4 5 6 7

Job/Part Power unit assembly Screw Plate Shift position switch Clip Bushing Bolt Shift bracket

7050

Q’ty

Remarks Refer to “POWER UNIT” on page 5-4.

2 1 1 1 1 2 1 Continued on next page.

7-10

BRKT

SHIFT ROD ASSEMBLY

E 7

12 18 Nm (1.8 m • kgf, 13 ft • Ib)

13 14 15

16 20

4 × 16 mm

6 × 25 mm

6 × 40 mm

4 5 21 17

3 A

6 × 12 mm

7 A

11 9 10

Order 8 9 10 11 12 13 14 15 16

7050

Job/Part Washer Clip Bushing Shift rod lever Bolt Spring Ball Cotter pin Washer

Q’ty 1 1 1 1 1 1 1 1 1

Remarks

Continued on next page.

7-11

BRKT

SHIFT ROD ASSEMBLY

E 7

12 18 Nm (1.8 m • kgf, 13 ft • Ib)

13 14 15

16 20

4 × 16 mm

6 × 25 mm

6 × 40 mm

4 5 21 17

3 A

6 × 12 mm

7 A

11 9 10

Order 17 18 19 20 21 22 23 24

7050

Job/Part Bolt Bracket Bolt Shift rod bracket Bushing Shift rod Grommet O-ring

Q’ty 2 1 2 1 2 1 1 1

Remarks

For installation, reverse the removal procedure.

7-12

BRKT

BOTTOM COWLING

REMOVING/INSTALLING THE BOTTOM COWLING 6 7 8

5 6 × 12 mm 6 × 20 mm

6 × 30 mm

6 × 16 mm

11 2

24 13

10 3

14 8 × 35 mm

21 23 28 29

22 27 26 19 19 17 18 16 20 6 × 20 mm

7060

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Power unit Bolt Bolt Spring hook Spring Bolt Washer Clamp lever Wave washer Bushing Clamp lever

Q’ty

Remarks Refer to “POWER UNIT” on page 5-4.

4 2 2 2 2 2 2 2 4 2 Continued on next page.

7-13

BRKT

BOTTOM COWLING

E 7

6 7 8

5 6 × 12 mm 6 × 20 mm

6 × 30 mm

6 × 16 mm

11 2

24 13

10 3

14 8 × 35 mm

21 23 28 29

22 27 26 19 19 17 18 16 20 6 × 20 mm

7060

Order 11 12 13 14 15 16 17 18 19

Job/Part Clamp plate Bolt Bracket Trailer switch Bolt Adaptor Gasket Hose joint Grommet

Q’ty 2 2 1 1 1 1

Remarks

For water hose and PTT lead It differs on specification 17 to 21

1 1 1 Continued on next page.

7-14

BRKT

BOTTOM COWLING

E 7

6 7 8

5 6 × 12 mm 6 × 20 mm

6 × 30 mm

6 × 16 mm

11 2

24 13

10 3

14 8 × 35 mm

21 23 28 29

22 27 26 19 19 17 18 16 20 6 × 20 mm

7060

Order 20 21 22 23 24 25 26 27 28 29

Job/Part Hose Bolt Bottom cowling Grommet Water outlet Cap Collar Grommet Collar Grommet

Q’ty 1 4 1 2 1 3 4 4 4 4

Remarks

For installation, reverse the removal procedure.

7-15

BRKT

UPPER CASE ASSEMBLY

REMOVING/INSTALLING THE UPPER CASE ASSEMBLY 10 Nm (1.0 m • kgf, 7.2 ft • Ib)

1 6 × 45 mm

5 4

10 5

2 LT LT

572

53 Nm (5.3 m • kgf, 38 ft • Ib)

11 16

7 15

LT LT

572

6 12

13 9

10 × 40 mm

14 6 × 10 mm

73 Nm (7.3 m • kgf, 53 ft • Ib)

Order

Job/Part

Q’ty

Lower unit

Bottom cowling 1 2 3 4 5 6

Bolt Oil pump assembly Seal Dowel pin O-ring Bolt

7070

Remarks Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1 and “LOWER UNIT (COUNTER ROTATION MODELS)” on page 6-26. Refer to “BOTTOM COWLING” on page 7-13.

6 1 1 2 2 4 Continued on next page. 7-16

BRKT

UPPER CASE ASSEMBLY

E 7

10 Nm (1.0 m • kgf, 7.2 ft • Ib)

1 6 × 45 mm

5 4

10 5

2 LT LT

572

53 Nm (5.3 m • kgf, 38 ft • Ib)

11 16

7 15

LT LT

572

6 12

13 9

10 × 40 mm

14 6 × 10 mm

73 Nm (7.3 m • kgf, 53 ft • Ib)

Order 7 8 9 10 11 12 13 14 15 16

Job/Part Lower mount cover Grease nipple Bolt Damper Nut Nut Washer Ground lead Washer Upper case assembly

Q’ty 2 1 1 2 2 2 2 1 2 1

Remarks

For installation, reverse the removal procedure.

7-17

7070

BRKT

UPPER CASE ASSEMBLY

E 7

DISASSEMBLING/ASSEMBLING THE OIL PUMP

4 Nm (0.4 m • kg, 2.9 ft • Ib)

2 4 A

3 5

9 8 7 6

1 7070

Order 1 2 3 4 5 6 7 8 9

Job/Part Screw Gasket Shaft O-ring O-ring Housing Gasket Oil seal Oil seal

Q’ty 10 1 1 1 1 1 1 2 1

Remarks Not reusable

Not reusable

For assembly, reverse the disassembly procedure.

7-17-1

BRKT

UPPER CASE ASSEMBLY

DISASSEMBLING THE OIL PUMP ASSEMBLY 1. Remove: • Cover 1 • Gasket 2 • Shaft 3 • O-ring 4 • O-ring 5 • Housing 6 • Gasket 7

3 5

7 6

CHECKING THE OIL PUMP ASSEMBLY 1. Check: • Shaft Cracks/wear → Replace. 2. Check: • Oil seals • O-rings Tears → Replace. 3. Check: • Oil passage Dirt/residue → Clean.

ASSEMBLING THE OIL PUMP ASSEMBLY 1. Install: • Oil seal Bearing installer: YB-41446

7-17-2

BRKT

UPPER CASE ASSEMBLY

2. Install: • Oil seal Bearing cup installer: YB-06167

3. Install: • Oil seals Roller bearing installer/remover: YB-06432-1A

4. Install: • Gasket 1 • Housing 2 • O-ring 3 • O-ring 4 • Shaft 5 • Gasket 6 • Cover 7

4 5

3 T.

Screw: 4 Nm (0.4 m • kg, 2.9 ft • lb)

NOTE: When installing the oil pump assembly onto the upper case assembly, pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly.

1 2

7-17-3

BRKT

UPPER CASE ASSEMBLY

E 7

DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY 8 × 45 mm

1 4

6 × 15 mm

12 × 193 mm

572

10 20 Nm (2.0 m • kgf, 14 ft • Ib) 8 × 40 mm

16 17

18 19

572

11 14 22 A

7 5 6

20 9

Order 1 2 3 4 5 6 7 8 9

Job/Part Bolt Upper mount rubber Bolt Plate Bolt Washer Rubber Lower mount rubber Washer

14 × 235 mm

7080

Q’ty 3 1 2 1 2 2 2 2 2

Remarks

Continued on next page.

7-18

BRKT

UPPER CASE ASSEMBLY

E 7

8 × 45 mm

1 4

6 × 15 mm

12 × 193 mm

572

10 20 Nm (2.0 m • kgf, 14 ft • Ib) 8 × 40 mm

16 17

18 19

572

11 14 22 A

7 5 6

20 9

Order 10 11 12 13 14 15 16 17 18

Job/Part Bolt Muffler assembly Gasket Rubber gasket Rubber seal Grommet Screw Baffle plate Damper

14 × 235 mm

7080

Q’ty 4 1 1 1 1 1 2 1 1

Remarks

Not reusable

Continued on next page.

7-19

BRKT

UPPER CASE ASSEMBLY

E 7

8 × 45 mm

1 4

6 × 15 mm

12 × 193 mm

572

10 20 Nm (2.0 m • kgf, 14 ft • Ib) 8 × 40 mm

16 17

18 19

572

11 14 22 A

7 5 6

20 9

Order 19 20 21 22

Job/Part Grommet Circlip Drive shaft bushing Upper case

14 × 235 mm

7080

Q’ty 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-20

BRKT

OIL PAN

DISASSEMBLING/ASSEMBLING THE OIL PAN 22 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm

9 20 19 18

10 4

572

6 × 30 mm

572

2 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm 13 LT

572

Job/Part Bolt Bolt Muffler Dowel pin Spacer Grommet Water pipe Rubber seal

6 × 50 mm

11 A

6 × 70 mm 11 Nm (1.1 m • kgf, 8.0 ft • Ib)

Order 1 2 3 4 5 6 7 8

572

7090

Q’ty 6 1 1 2 1 1 1 1

Remarks

Continued on next page.

7-21

BRKT

OIL PAN

E 7

22 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm

9 20 19 18

10 4

572

6 × 30 mm

572

2 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm 13 LT

572

Job/Part Exhaust manifold gasket Plate Exhaust seal Bolt Exhaust manifold Gasket Bolt Oil pan

6 × 50 mm

11 A

6 × 70 mm 11 Nm (1.1 m • kgf, 8.0 ft • Ib)

Order 9 10 11 12 13 14 15 16

572

7090

Q’ty 2 1 1 4 1 1 12 1

Remarks Not reusable

Not reusable

Continued on next page.

7-22

BRKT

OIL PAN

E 7

22 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm

9 20 19 18

10 4

572

6 × 30 mm

572

2 11 Nm (1.1 m • kgf, 8.0 ft • Ib) 6 × 25 mm 13 LT

572

Job/Part Bolt Collar Oil strainer Rubber gasket Gasket Exhaust guide

6 × 50 mm

11 A

6 × 70 mm 11 Nm (1.1 m • kgf, 8.0 ft • Ib)

Order 17 18 19 20 21 22

572

7090

Q’ty 3 3 1 1 1 1

Remarks

Not reusable Not reusable For assembly, reverse the disassembly procedure.

7-23

BRKT

CLAMP BRACKETS

REMOVING/INSTALLING THE CLAMP BRACKETS

7100

Order

1 2 3 4 5 6 7 8

Job/Part Upper case assembly Grease nipple Ground lead Bolt Ground lead Anode bracket Anode Trim sensor Self-locking nut

Q’ty

Remarks Refer to “UPPER CASE ASSEMBLY” on page 7-16.

4 1 4 1 2 1 1 1 Continued on next page.

7-24

BRKT

CLAMP BRACKETS

E 7

7100

Order 9 10 11 12 13 14 15 16 17

Job/Part Cam Bolt Clamp bracket bolt Starboard clamp bracket Port clamp bracket Bushing Grease nipple Ground lead Swivel bracket assembly

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 2 1 1 1

Remarks

For installation, reverse the removal procedure.

7-25

BRKT

STEERING ARM

REMOVING/INSTALLING THE STEERING ARM

7110

Order

1 2 3 4 5 6 7 8 9

Job/Part Upper case assembly Circlip Steering arm yoke Washer Washer O-ring Steering arm Washer Bushing Swivel bracket assembly

Q’ty

Remarks Refer to “UPPER CASE ASSEMBLY” on page 7-16.

1 1 1 1 1 1 1 2 1 For installation, reverse the removal procedure. 7-26

BRKT

SWIVEL BRACKET ASSEMBLY

DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY

7120

Order 1 2 3 4 5 6

Job/Part Steering arm Nut Trim stopper Bolt Spring holder Spring Pin

Q’ty

Remarks Refer to “STEERING ARM” on page 7-26.

2 2 1 1 1 2 Continued on next page.

7-27

BRKT

SWIVEL BRACKET ASSEMBLY

E 7

7120

Order 7 8 9 10 11

Job/Part Starboard tilt stop lever Port tilt stop lever Bushing Bushing Tilt stop lever joint assembly

Qâ&#x20AC;&#x2122;ty 1 1 2 2 1

Remarks

For assembly, reverse the disassembly procedure.

7-28

BRKT

POWER TRIM AND TILT UNIT

REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT

7130

Order 1 2 3 4 5 6

Job/Part Tilt up the outboard Power trim and tilt lead Plastic locking tie Bolt Ground lead Circlip Upper mounting pin

Qâ&#x20AC;&#x2122;ty 2 3 1 1 1 1

Remarks

Not reusable

Continued on next page.

7-29

BRKT

POWER TRIM AND TILT UNIT

E 7

7130

Order 7 8 9 10 11

Job/Part Bolt Washer Lower mounting pin Power trim and tilt unit Collar

Qâ&#x20AC;&#x2122;ty 2 2 1 1 6

Remarks

For installation, reverse the removal procedure.

7-30

BRKT

POWER TRIM AND TILT UNIT

REMOVING THE POWER TRIM AND TILT UNIT WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.

NOTE: Tilt up the outboard and then turn the tilt stop levers 1 to support it. Remove: • Power trim and tilt unit NOTE: Slightly lower the tilt ram assembly and then remove the power trim and tilt unit.

7140

BLEEDING THE POWER TRIM AND TILT UNIT NOTE: Install the power trim and tilt unit onto the outboard before bleeding. Bleed: • Air bubbles (from the power trim and tilt unit) Bleeding steps (1) Connect the battery leads to the battery. (2) Loosen the manual valve 1 by turning it counterclockwise until it stops.

7150

7-31

BRKT

POWER TRIM AND TILT UNIT

(3) Tilt up the outboard fully, then release it, and let it lower by its own weight. (4) Tighten the manual valve by turning it clockwise. (5) Let the power trim and tilt fluid settle for about 5 minutes. (6) Push and hold the power trim and tilt switch in the up position until the outboard is fully tilted up. (7) Turn the tilt stop levers to support the outboard. Then, let the power trim and tilt fluid settle for about 5 minutes. (8) Remove the reservoir cap 2 and check that fluid is up to the brim as shown. Add fluid if the level is below the brim. (9) Install the power trim and tilt reservoir cap. (10) Repeat the above steps two or three times until the power trim and tilt fluid is at the correct level.

7160

7170

7-32

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR

7180

Order

1 2 3 4 5 6 7 8

Job/Part Power trim and tilt unit Reservoir cap Bolt Reservoir Bolt Power trim and tilt motor O-ring Drive pin Gear pump housing filter

Q’ty

Remarks Refer to “POWER TRIM AND TILT UNIT” on page 7-29.

1 3 1 4 1 1 1 1 For installation, reverse the removal procedure.

7-33

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

WARNING • To prevent the hydraulic fluid from spurting out due to internal pressure, the outboard should be kept fully tilted up (the tilt rod at full length). • After removing the power trim and tilt motor or reservoir, do not push the tilt ram down. This may cause hydraulic fluid to spurt out from the port.

CAUTION: Do not wipe hydraulic system components with rags, paper, tissues, or the like, as fibers from such material will cause malfunctions if they enter the system.

CHECKING THE RESERVOIR 1. Drain: • Power trim and tilt fluid 2. Check: • Reservoir Cracks/damage/leaks → Replace.

CHECKING THE GEAR PUMP HOUSING FILTER Check: • Gear pump housing filter Damage/tears → Replace. Foreign matter → Clean.

7-34

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

INSTALLING THE POWER TRIM AND TILT MOTOR 1. Install: • Gear pump housing filter 1 • Drive pin 2 2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II

7190

NOTE: Add power trim and tilt fluid until it reaches the top of the gear pump housing.

3. Bleed: • Air bubbles NOTE: • Remove all of the air bubbles with a syringe or suitable tool as shown. • Turn the gear pump gears with a screwdriver and then remove any air between the gear teeth.

7200

4. Install: • O-ring 1 • Power trim and tilt motor 2 • Bolt 3 NOTE: Align the armature shaft with the recess in the drive pin. 7210

7-35

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

FILLING THE RESERVOIR WARNING To prevent the hydraulic fluid from spurting out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Reservoir Recommended power trim and tilt fluid ATF Dexron II 2. Check: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. 7220

BLEEDING THE POWER TRIM AND TILT UNIT NOTE: This bleeding must be done before installing the power trim and tilt unit onto the outboard. 1. Bleed: • Air bubbles (from the power trim and tilt unit) Bleeding steps (1) Set the power trim and tilt unit upright. (2) Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully compressed. 7230

NOTE: If the rams will not go down, refer to the following. A. Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully extended. Then, reverse the leads on the battery terminals until the trim and tilt ram assemblies are fully compressed.

7240

7-36

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

B. If step A was unsuccessful, connect the leads on the battery terminals and fully compress the tilt ram assembly by hand. C. If step B was unsuccessful, loosen the manual valve, compress the trim and tilt ram assemblies fully by hand, and then tighten the manual valve. Then, compress and extend the trim and tilt ram assemblies by connecting the leads on the battery terminals in the up and down positions. D. If step C was unsuccessful, disassemble, check, and correct any problems with the power trim and tilt unit.

(3) Connect the leads on the battery terminals in the up position until the trim and tilt ram assemblies are fully extended.

7240

(4) Remove the power trim and tilt reservoir cap and check that fluid is up to the brim as shown. Add power trim and tilt fluid if the level is below the brim. (5) Repeat the above steps two or three times until the fluid is at the correct level. 7220

2. Check: â&#x20AC;˘ Power trim and tilt unit operation Unsmooth operation â&#x2020;&#x2019; Bleed the power trim and tilt unit again.

7-37

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

MEASURING THE HYDRAULIC PRESSURE Check: • Hydraulic pressure Out of specification → Repair. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm2) (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm2) NOTE: Before measuring the hydraulic pressure, bleed the power trim and tilt unit.

Measuring steps (1) Fully tilt up the power trim and tilt ram assemblies. (2) Remove the circlip 1. (3) Remove the manual valve 2 and install the up-relief valve attachment and hydraulic pressure gauge and tighten them to the specified torque. Up-relief valve attachment ...... 3 90890-06773 Hydraulic pressure gauge ........ 4 90890-06776

7250

Hydraulic pressure gauge 9 Nm (0.9 m • kgf, 6.5 ft • lb) Up-relief valve attachment 4 Nm (0.4 m • kgf, 2.9 ft • lb)

NOTE: Remove the manual valve and then quickly attach the special tools before any fluid comes out.

7260

7-38

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

(4) Connect the leads on the battery terminals in the down position until the power trim and tilt ram assemblies are fully compressed.

7230

(5) Connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. Then, measure the hydraulic pressure. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm2)

7240

(6) After measuring the hydraulic pressure, remove the special tools and quickly attach the down-relief valve attachment. Hydraulic pressure gauge ........ 4 90890-06776 Down-relief valve attachment. 5 90890-06774 7270

Hydraulic pressure gauge 9 Nm (0.9 m • kgf, 6.5 ft • lb) Down-relief valve attachment 4 Nm (0.4 m • kgf, 2.9 ft • lb)

(7) Remove the reservoir cap and check that fluid is up to the brim as shown. Add fluid if the level is below the brim. (8) Install the reservoir cap. (9) Connect the leads on the battery terminals in the down position until the power trim and tilt ram assemblies are fully compressed. Then, measure the hydraulic pressure.

7220

Hydraulic pressure (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm2)

7-39

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

(10) After measuring the hydraulic pressure, connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. (11) Remove the special tools. (12) Install the manual valve and circlip. NOTE: After measuring the hydraulic pressure, bleed the power trim and tilt unit.

7280

7240

7-40

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT

7290

Order

1 2 3 4 5 6

Job/Part Reservoir and power trim and tilt motor Manual valve Tilt ram end screw Tilt ram assembly O-ring Bolt Gear pump unit

Q’ty

Remarks Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-33.

1 1 1 2 3 1 Continued on next page.

7-41

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

E 7

7290

Order 7 8 9 10 11 12

Job/Part Check valve assembly Gear pump Shuttle valve Check valve Up-relief valve assembly Down-relief valve assembly

Qâ&#x20AC;&#x2122;ty 1 1 2 2 1 1

Remarks

For installation, reverse the removal procedure.

7-42

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

REMOVING THE TILT RAM END SCREW Loosen: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548 7300

NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

REMOVING THE GEAR PUMP UNIT Remove: • Bolt 1 • Gear pump unit 2 • O-ring 3 • Check valve 4

7310

NOTE: Place a container under the power trim and tilt unit.

DISASSEMBLING THE GEAR PUMP UNIT 1. Remove: • Bolt 1 • Pump gear 2 • Up-relief valve assembly 3 • Ball (4.76 mm/0.187 in) 4 • Shuttle valve 5 • Ball (3.18 mm/0.125 in) 6

7320

NOTE: When removing the pump gears, note their original direction and position for proper assembly.

7-43

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

2. Remove: • Check valves 1 and 2 NOTE: To remove the check valves, cover the gear pump housing with a clean cloth and then blow compressed air through holes a and b. 7330

CHECKING THE TILT RAM Check: • Tilt ram Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper)

CHECKING THE GEAR PUMP UNIT Check: • Shuttle valves 1 • Check valve assemblies 2 Clogs/damage/wear → Replace. • Pump gears 3 Damage/wear → Replace the gear pump unit. • Up-relief valve assembly 4 • Down-relief valve assembly 5 Damage/wear → Replace the gear pump unit. • Balls 6 Damage/wear → Replace.

7340

7-44

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

ASSEMBLING THE GEAR PUMP UNIT CAUTION: Install all components in their original direction and position for proper assembly and operation.

1. Install: • Balls (3.18 mm/0.125 in) 1 • Shuttle valves 2 NOTE: Apply grease to the balls to prevent them from falling out of the gear pump. 7350

2. Install: • O-ring 1 • Ball (3.18 mm/0.125 in) 2 • Up-relief valve pin 3 • Spring 4 • Up-relief valve 5 • Up-relief valve assembly 6 7360

3. Install: • O-rings 1 • Check valves 2 • Balls (4.76 mm/0.187 in) 3 • Pump gears 4

4. Install: • Gear pump 1 • Bolt 2 • Filter 3 • O-ring 4 • Down-relief valve 5 • Filter 6

7370

NOTE: Tighten the bolts evenly and make sure the pump gears turn smoothly. 7380

7-45

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

INSTALLING THE GEAR PUMP UNIT 1. Install: • O-rings 1 • Ball 2 • Pin 3 • Check valve 4 • Check valve assembly 5 NOTE: When installing the check valve assembly, make sure the pin is on the tilt ram cylinder side as shown.

7390

2. Install: • Gear pump unit 1 • Bolt 2

7400

INSTALLING THE TILT RAM ASSEMBLY WARNING To prevent the hydraulic fluid from spurting out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Tilt ram cylinder Recommended power trim and tilt fluid ATF Dexron II NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

7410

7-46

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through the hole a until the fluid level is to the top of the gear pump unit.

7420

3. Install: • Tilt ram assembly NOTE: Place the tilt ram end screw at the bottom of the tilt ram and install the tilt ram assembly into the tilt ram cylinder. 7430

4. Tighten: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548

7300

7-47

Tilt ram end screw 130 Nm (13 m • kgf, 94 ft • lb)

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON

7440

Order

1 2 3 4 5 6 7

Job/Part Tilt ram assembly and gear pump unit Trim ram end screw Trim ram O-ring Seal ring Free piston O-ring Piston ring

Q’ty

Remarks Refer to “TILT RAM ASSEMBLY AND GEAR PUMP UNIT” on page 7-41.

2 2 2 2 1 1 1 For installation, reverse the removal procedure.

7-48

BRKT Å

TRIM RAM ASSEMBLIES AND FREE PISTON

REMOVING THE TRIM RAM END SCREWS

Loosen: • Trim ram end screw End screw wrench YB-06175-1A / 90890-06548 Å For USA and Canada ı For worldwide

7450

NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

REMOVING THE FREE PISTON 1. Drain: • Power trim and tilt fluid NOTE: After removing the trim ram assemblies, drain the fluid from the power trim and tilt unit. 2. Install: • Trim ram assemblies 1 NOTE: Finger-tighten the trim ram assemblies and then cover the tilt cylinder openings with a clean cloth. 3. Remove: • Free piston 2

7460

WARNING Never look into the tilt cylinder opening because the free piston and hydraulic fluid may be expelled out forcefully.

NOTE: Remove the free piston by blowing compressed air through the hole a.

7470

7-49

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

CHECKING THE TRIM RAMS Check: • Trim ram Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper)

CHECKING THE FREE PISTON Check: • Free piston Excessive scratches → Replace.

CHECKING THE TRIM RAM CYLINDERS Check: • Trim ram cylinder Cracks/excessive scratches → Replace the power trim and tilt unit.

INSTALLING THE FREE PISTON 1. Fill: • Fluid passages Recommended power trim and tilt fluid ATF Dexron II Quantity 30 cm3 (1.0 US oz, 1.1 lmp oz) NOTE: • Hold the power trim and tilt unit in a vise using aluminum plates on both sides. • Add power trim and tilt fluid through the hole a.

7480

7-50

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

2. Install: • Piston ring 1 • O-ring 2 • Free piston 3 NOTE: Push the free piston into the tilt ram cylinder until it bottoms out. 7490

INSTALLING THE TRIM RAMS WARNING Do not push the trim rams down while installing them into the trim ram cylinders. Otherwise, the hydraulic fluid may spurt out from the unit. 1. Fill: • Trim ram cylinders Recommended power trim and tilt fluid ATF Dexron II NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides. 7500

2. Fill: • Fluid passages Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through holes a, b and c until all of the passages are filled.

7510

7-51

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

3. Install: • Trim ram assemblies 1 NOTE: Place each trim ram end screw at the bottom of each trim ram and install them into the trim ram cylinders. 7520

4. Tighten: • Trim ram end screw

End screw wrench YB-06175-1A / 90890-06548

Trim ram end screw 80 Nm (8.0 m • kgf, 58 ft • lb)

7450

Å For USA and Canada ı For worldwide

7-52

ELEC

â&#x20AC;&#x201C;

CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS......................................................................... 8-1 (Port view) ................................................................................................ 8-1 (Starboard view) ...................................................................................... 8-2 (Front view) .............................................................................................. 8-3 (Aft view) .................................................................................................. 8-4 (Top view)................................................................................................. 8-5 WIRE HARNESS ............................................................................................. 8-6 ELECTRICAL COMPONENTS ANALYSIS ..................................................... 8-8 DIGITAL CIRCUIT TESTER....................................................................... 8-8 MEASURING THE PEAK VOLTAGE........................................................ 8-8 PEAK VOLTAGE ADAPTOR..................................................................... 8-8 MEASURING A LOW RESISTANCE........................................................ 8-9 IGNITION SYSTEM....................................................................................... 8-10 CHECKING THE BATTERY..................................................................... 8-11 CHECKING THE FUSES ......................................................................... 8-11 MEASURING THE IGNITION COIL ASSEMBLY................................... 8-11 CHECKING THE IGNITION SPARK GAP ............................................... 8-12 MEASURING THE IGNITION SYSTEM PEAK VOLTAGE .................... 8-13 IGNITION CONTROL SYSTEM .................................................................... 8-15 CHECKING THE BATTERY..................................................................... 8-16 CHECKING THE FUSES ......................................................................... 8-16 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.............. 8-16 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE ......................................................................... 8-16 CHECKING THE OIL PRESSURE SWITCH CONTINUITY..................... 8-17 MEASURING THE THROTTLE POSITION SENSOR ............................ 8-18 FUEL CONTROL SYSTEM............................................................................ 8-19 CHECKING THE BATTERY..................................................................... 8-20 CHECKING THE FUSES ......................................................................... 8-20 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE ......................................................................... 8-20 MEASURING THE THROTTLE POSITION SENSOR ............................ 8-20 CHECKING THE FUEL INJECTORS....................................................... 8-21

ELEC

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STARTING SYSTEM..................................................................................... 8-22 CHECKING THE BATTERY..................................................................... 8-23 CHECKING THE FUSES ......................................................................... 8-23 CHECKING THE WIRE HARNESS CONTINUITY .................................. 8-23 CHECKING THE WIRE CONNECTIONS ................................................ 8-23 CHECKING THE STARTER RELAY ........................................................ 8-23 CHECKING THE SHIFT POSITION SWITCH CONTINUITY .................. 8-24 STARTER MOTOR ........................................................................................ 8-25 DISASSEMBLING/ASSEMBLING THE STARTER MOTOR.................. 8-25 REMOVING THE STARTER MOTOR PINION ....................................... 8-28 CHECKING THE STARTER MOTOR PINION ........................................ 8-28 CHECKING THE ARMATURE ................................................................ 8-28 MEASURING THE BRUSHES ................................................................ 8-29 CHECKING THE MAGNETIC SWITCH RELAY...................................... 8-30 CHARGING SYSTEM.................................................................................... 8-31 CHECKING THE FUSES ......................................................................... 8-32 CHECKING THE BATTERY..................................................................... 8-32 MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE .......... 8-32 MEASURING THE RECTIFIER/REGULATOR OUTPUT PEAK VOLTAGE .................................................................................... 8-32 POWER TRIM AND TILT SYSTEM .............................................................. 8-33 CHECKING THE BATTERY..................................................................... 8-34 CHECKING THE POWER TRIM AND TILT RELAY................................ 8-34 CHECKING THE TRAILER SWITCH CONTINUITY................................ 8-35 MEASURING THE TRIM SENSOR RESISTANCE................................. 8-35 POWER TRIM AND TILT MOTOR ................................................................ 8-36 DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR.......................................................................................... 8-36 REMOVING THE STATOR ..................................................................... 8-38 REMOVING THE BRUSH ....................................................................... 8-38 CHECKING THE BRUSH ........................................................................ 8-38 CHECKING THE ARMATURE ................................................................ 8-39 INSTALLING THE BRUSH ..................................................................... 8-40 INSTALLING THE ARMATURE ............................................................. 8-40 INSTALLING THE STATOR ................................................................... 8-40

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

ELECTRICAL COMPONENTS

(Port view)

8010

1 2 3 4 5 6

Oil pressure switch Throttle position sensor Idle speed control valve Intake air pressure sensor Fuel injector High-pressure fuel pump

8-1

ELEC

â&#x20AC;&#x201C;

ELECTRICAL COMPONENTS

(Starboard view)

2 5

8020

1 2 3 4 5 6

Ignition coil Engine cooling water temperature sensor Starter motor Relay (magnetic switch) Battery lead terminal Junction box assembly

8-2

ELEC

â&#x20AC;&#x201C;

ELECTRICAL COMPONENTS

(Front view)

1 8 2 4 7

8030

1 2 3 4 5 6 7 8

Fuse (30A) Main relay ECM Rectifier/regulator Intake air temperature sensor Power trim and tilt relay Starter relay Fuse (20A)

8-3

ELEC

â&#x20AC;&#x201C;

ELECTRICAL COMPONENTS

(Aft view)

8040

1 Spark plug 2 Spark plug lead

8-4

ELEC

â&#x20AC;&#x201C;

ELECTRICAL COMPONENTS

(Top view)

2 3

7 4 6

5 8

8050

1 2 3 4 5 6 7 8

Fuel injector Intake air pressure sensor Idle speed control valve Throttle position sensor Trailer switch Relay (magnetic switch) Starter Lighting coil

8-5

â&#x20AC;&#x201C;

ELEC

WIRE HARNESS

3 4

5 B 6

7 8

G G H H

6 5 4 3 2 1 12 11 10 9 8 7

6 9 3 4 5

B P

B/W P

R/Y

B/R R/Y

B/Y B

B G

Y W

Sb P

0 A

P/B P/W

P/B

R Lg

R/Y Y

R/Y

L/W L/W

D E

R Lg

Br R/B

F G G H

R R

W/B

B B B B B B B/R B/W W/B B/Y

R/Y W P G G P/W P/B L/W

8060

Connect to: 1 Ground 2 ECM 3 Ignition coil 4 Ignition coil 5 Engine cooling water temperature sensor 6 Trim meter 7 Trim sensor 8 Remote control

9 0 A B C D E F G H

Warning lamp PTT relay Starter relay Main relay Trailer switch Starter relay Rectifier/regulator Starter motor Fuse 20A Fuse 30A

B Br G Lg P R Sb W Y 8-6

: Black : Brown : Green : Light green : Pink : Red : Sky blue : White : Yellow

B/R B/W B/Y L/W P/B P/W R/B R/Y W/B

: Black/red : Black/white : Black/yellow : Blue/white : Pink/black : Pink/white : Red/black : Red/yellow : White/black

ELEC

â&#x20AC;&#x201C;

WIRE HARNESS

4 A 6 3

9 9

3 1 2

W/B W/R B

B B

B/Y

B B

5 7

R/Y

R/Y B

R/Y

P/W

R/Y

B P

P/G

G/B

G R/Y

G/Y

R/Y

8 9 0

R/Y

R/Y Pu/R

B L/Y

L R/Y

Pu/B R/Y

Pu/Y

Pu/G

R/Y

G/R

B O O P/G P L Pu/R Pu/G Pu/B Pu/Y R/Y G/R

G/B G/Y G B/Y L/Y P/W W/B W/R B B

8070

Connect to: 1 Pulser coil 2 ECM 3 Ground lead 4 Intake air temperature sensor 5 Oil pressure switch 6 Idle speed control valve 7 Throttle position sensor

8 Intake air pressure sensor 9 Fuel injectors 0 Shift position switch A High-pressure fuel pump B G L

: Black : Green : Blue 8-7

O P B/Y G/B G/R G/Y L/Y P/G P/W

: Orange : Pink : Black/yellow : Green/black : Green/red : Green/yellow : Blue/yellow : Pink/green : Pink/white

Pu/B Pu/G Pu/R Pu/Y R/Y W/B W/R

: Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : White/black : White/red

ELEC

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ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER

Digital tester J-39299 / 90890-06752 NOTE: “ ” indicates a continuity of electricity which means a closed circuit at the respective switch position.

8080

MEASURING THE PEAK VOLTAGE

NOTE: • When checking the condition of the ignition system it is useful to know the peak voltage. • Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defective, the peak voltage will be lower than specification. • If the peak voltage measurement is not within specification the engine will not operate properly.

PEAK VOLTAGE ADAPTOR

NOTE: The peak voltage adaptor should be used with the digital circuit tester.

Peak voltage adaptor YU-39991 / 90890-03169

8090

8-8

ELEC

–

ELECTRICAL COMPONENTS ANALYSIS

NOTE: • When measuring the peak voltage, set the selector to the DC voltage mode. • Make sure the peak voltage adaptor leads are properly installed in the digital tester. • Make sure the positive pin (the “+” mark facing up as shown) on the peak voltage adaptor is installed into the positive terminal of the digital tester. • The test harness is needed for the following tests.

8100

Measuring steps (1) Disconnect the coupler connections. (2) Connect the test harness between the couplers. (3) Connect the peak voltage adaptor probes to the connectors which are being checked. (4) Start or crank the engine and observe the measurement. 8110

MEASURING A LOW RESISTANCE

When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. To obtain the correct value, subtract the internal resistance from the displayed measurement. Correct value Displayed measurement – internal resistance NOTE: The internal resistance of the digital tester can be obtained by connecting both of its probes.

8-9

ELEC

â&#x20AC;&#x201C;

IGNITION SYSTEM

0 B R

G R

G G

7 2

1 1

R/Y R/Y

1 2

B B/R

W/R

W/B

B/R

R/Y R/Y W/B

W/R

B/W B/W R/Y R

A B

W/R W/B O

R/Y

W B B

25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12

31 32 33 34 35 36

13 14 15 16 17 18 19 20 21 22 23 24

30 29 28 27 26 25

12 11 10 9 8 7 6 5 4 3 2 1

36 35 34 33 32 31

24 23 22 21 20 19 18 17 16 15 14 13

P :2 W/B : D W/R : E O :F W :P

B/R : T B/W : Z

8120

1 Spark plugs 2 Ignition coils 3 Throttle position (TPS) 4 Pulser coils 5 10P coupler 6 ECM 7 Lighting coil 8 Rectifier/regulator

sensor

9 0 A B B G O P

Battery Fuse (30A) Fuse (20A) Main relay : Black : Green : Orange : Pink 8-10

R W B/R B/W R/Y W/B W/R

: Red : White : Black/red : Black/white : Red/yellow : White/black : White/red

ELEC

–

IGNITION SYSTEM

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

CHECKING THE FUSES

1. Check: • Fuse holder continuity No continuity → Check the fuse holder leads. 2. Check: • Fuse holder lead continuity No continuity → Replace the fuse holder. Continuity → Check the fuse.

3. Check: • Fuse continuity No continuity → Replace. • Fuse rating Out of specification → Replace. Fuse rating 1: 12 V - 20 A 2: 12 V - 30 A

8180

MEASURING THE IGNITION COIL ASSEMBLY Measure: • Ignition coil assembly resistance Out of specification → Replace. Ignition coil assembly resistance 18.97 - 35.23 kΩ (For cylinder No. 1, 4) 18.55 - 34.45 kΩ (For cylinder No. 2, 3)

8240

8-11

ELEC

–

IGNITION SYSTEM

CHECKING THE IGNITION SPARK GAP

WARNING • Do not touch any of the connections of the spark gap tester lead wires. • Do not let sparks leak out of the removed spark plug cap. • Keep flammable gas or liquids away, since this test can produce sparks.

8130

Check: • Ignition spark gap Spark is weak → Check the ignition system.

Checking steps (1) Remove the spark plugs from the engine. (2) Connect a spark plug cap to the spark gap tester. (3) Set the spark gap length on the adjusting knob. Spark gap tester YM-34487 / 90890-06754

8160

(4) Crank the engine and observe the spark through the discharge window of the spark gap tester.

8170

8-12

ELEC

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IGNITION SYSTEM

MEASURING THE IGNITION SYSTEM PEAK VOLTAGE

WARNING When checking the peak voltage do not touch any of the connections of the digital tester lead wires.

NOTE: • If there is no spark or the spark is weak, continue with the ignition system test. • If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another component.

1. Measure: NOTE: • The peak voltage adaptor should be used with the digital circuit tester. • When measuring the peak voltage, set the selector to the DC voltage mode.

B/R

Peak voltage adaptor YU-39991 / 90890-03169 • ECM unit output peak voltage Below specification → Check the wire harness. Correct the wire harness → Replace the ECM unit.

B/W

ECM unit output peak voltage Black/red (B/R) – Ground Black/white (B/W) – Ground

8190

r/min V

Loaded

Unloaded

Cranking 5.0

122

1,500

3,500

242

245

Test harness (2-pin) 90890-06792

8-13

ELEC

–

IGNITION SYSTEM

E 2. Measure: • Pulser coil output peak voltage Below specification → Replace the pulser coil.

8210

Pulser coil output peak voltage White/black (W/B) – Black (B) White/red (W/R) – Black (B)

W/B B W/R r/min V

Loaded

Unloaded

Cranking 3.5

1,500

3,500

3.0

Test harness (3-pin) 90890-06791

8-14

â&#x20AC;&#x201C;

ELEC

IGNITION CONTROL SYSTEM

7 8

8 9 R

9 4

W/B

W/R W/R

B W/B

W/B W/R

W/R

2 3

6 1

B/Y

5 B

P B/Y

B P/W R/Y R

P B B/Y

B P

P/W

25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12

31 32 33 34 35 36

13 14 15 16 17 18 19 20 21 22 23 24

30 29 28 27 26 25

12 11 10 9 8 7 6 5 4 3 2 1

36 35 34 33 32 31

24 23 22 21 20 19 18 17 16 15 14 13

O :F P :2 B/Y : Q P/W : 6 R/Y : O W/B : D W/R : E 8250

1 2 3 4 5 6 7 8 9

ECM Engine cooling water temperature sensor Oil pressure switch Pulser coils Throttle position sensor (TPS) Main relay Battery Fuse (30A) Fuse (20A)

B O P R B/Y P/W R/Y W/B W/R 8-15

: Black : Orange : Pink : Red : Black/yellow : Pink/white : Red/yellow : White/black : White/red

ELEC

–

IGNITION CONTROL SYSTEM

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page 8-11.

MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE

Refer to “MEASURING THE IGNITION SYSTEM PEAK VOLTAGE” on page 8-13.

MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE

Measure: • Engine cooling water temperature sensor resistance Out of specification → Replace. Engine cooling water temperature sensor resistance Black/yellow (B/Y) – Black (B) 5 ˚C (41 ˚F): 4.62 kΩ 20 ˚C (68 ˚F): 2.44 kΩ 100 ˚C (212 ˚F): 0.19 kΩ

8260

Measuring steps (1) Place the engine cooling water temperature sensor in a container filled with water. (2) Place a thermometer in the water. (3) Slowly heat the water. (4) Measure the resistance when the specified temperature is reached.

8-16

ELEC

–

IGNITION CONTROL SYSTEM

CHECKING THE OIL PRESSURE SWITCH CONTINUITY Measure: • Oil pressure switch continuity Out of specification → Replace. Mity vac YB-35956 / 90890-06756 8270

Oil pressure switch continuity pressure 150 kPa (1.5 kg/cm2, 21.33 psi) and below

8-17

ELEC

–

IGNITION CONTROL SYSTEM

MEASURING THE THROTTLE POSITION SENSOR

8280

NOTE: When measuring the output voltage, set the selector to the DC voltage mode. Measure: • Throttle position sensor output voltage Out of specification → Adjust the throttle position sensor. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 3-7. P

Throttle position sensor output voltage Pink (P) – Black (B) 0.732 ± 0.014 V Measuring steps (1) Connect the test harness (3-pin) as shown. Test harness (3-pin) 90890-06793 (2) Connect the battery leads to a 12-V battery. (3) Turn the engine switch to the on position. (4) Measure the throttle position sensor output voltage. (5) Start the engine and measure the output voltage again. NOTE: Make sure the throttle position sensor output voltage is within specification when the throttle is fully closed and fully opened.

8-18

ELEC

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FUEL CONTROL SYSTEM

R/Y

5 R/Y

W/B

W/R B

W/B

R/Y

W/R

1 #3

3 B P O

Pu/Y

R/Y R/Y

R/Y

Pu/R

R/Y O

Pu/R

R/Y

Pu/Y

B Y

B O P

G R/Y

R/Y Pu/G

R/Y R/Y R/Y

Pu/B

R/Y

Pu/B

Pu/G

G Y

B Y B

G/Y R/Y R/Y G

B/Y

R/Y

B B

G/B G/Y

B B

G/B

B/Y R/Y B/Y

R/Y

B B

G/R

R B

8 P/G

0 O

1 2 3 4 5 6 7 8 9 10 11 12

31 32 33 34 35 36

13 14 15 16 17 18 19 20 21 22 23 24

30 29 28 27 26 25

24 23 22 21 20 19 18 17 16 15 14 13

36 35 34 33 32 31

12 11 10 9 8 7 6 5 4 3 2 1

1 2 3 4 5 6 7 8 9

25 26 27 28 29 30

Fuel injectors Joint connector Throttle position sensor High-pressure fuel pump Pulser coil 10P connector ECM Main relay Fuse (30A)

B/Y : 1 P :2 P/G : 3 O :4 Pu/G : 9 Pu/Y : 0 R/Y : B

W/B W/R O G G/B G/Y G/R

:D :E :F :G :H :I :J

Pu/R : L Pu/B : M L :N R/Y : O B/Y : Q B/G : Y

P/G R

B B

B B/Y

+ -

B B/Y

0 Fuse (20A) A Battery B Engine cooling water temperature sensor C Intake air pressure sensor D Intake air temperature sensor E Idle speed control valve 8-19

B G L O P R Y B/Y G/B G/R

: Black : Green : Blue : Orange : Pink : Red : Yellow : Black/yellow : Green/black : Green/red

8290

G/Y P/G Pu/B Pu/G Pu/R Pu/Y R/Y W/B W/R

: Green/yellow : Pink/green : Purple/black : Purple/green : Purple/red : Purple/yellow : Red/yellow : White/black : White/red

ELEC

–

FUEL CONTROL SYSTEM

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page 8-11.

MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE

Refer to “MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE” on page 8-16.

MEASURING THE THROTTLE POSITION SENSOR

Refer to “MEASURING THE THROTTLE POSITION SENSOR” on page 8-18.

8-20

ELEC

–

FUEL CONTROL SYSTEM

CHECKING THE FUEL INJECTORS

1. Check: • Fuel injector operating sound No sound (no fuel is being sprayed) → Check the high-pressure fuel pump. 1 Checking steps (1) Start the engine. (2) Fully close the throttle valves. (3) Attach the screwdriver 1 onto the fuel injector body and check if all of the fuel injectors have a solenoid valve operating sound.

8320

2. Check: • High-pressure fuel pump operating sound Correct → Replace the fuel injector (no sound). No sound → Check the main relay. NOTE: • The high-pressure fuel pump should sound when the engine start switch is turned on. • Disconnect the Brown (Br) starter relay lead 1 to prevent the engine from starting.

1 8330

3. Check: • Main relay continuity Out of specification → Replace the main relay. Engine start switch

R R/Y R/Y G Y B

Lead color Red (R)

Red/yellow (R/Y)

OFF

8340

ON Correct → Replace the high-pressure fuel pump.

8-21

ELEC

â&#x20AC;&#x201C;

STARTING SYSTEM

2 5 Br R Br/W

1 R R Br/W

4 8350

1 2 3 4 5 6

Fuse (30A) 10P connector Starter relay Battery Relay (magnetic switch) Starter motor

B Br R Br/W

8-22

: Black : Brown : Red : Brown/white

ELEC

–

STARTING SYSTEM

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page 8-11.

CHECKING THE WIRE HARNESS CONTINUITY

Check: • Wire harness continuity No continuity → Replace.

CHECKING THE WIRE CONNECTIONS

Check: • Wire connections Poor connection → Properly connect.

CHECKING THE STARTER RELAY 1 +

Check: • Starter relay continuity No continuity → Replace.

Checking steps (1) Connect the tester and battery between the starter relay terminals.

3 4

Positive digital tester probe 1 → Starter relay terminal Negative digital tester probe 2 → Starter relay terminal Positive battery terminal → Brown lead 3 Negative battery terminal → Black lead 4

8360

(2) Check that there is continuity between the starter relay terminals.

8-23

ELEC

–

STARTING SYSTEM

CHECKING THE SHIFT POSITION SWITCH CONTINUITY

a b

Check: • Continuity No continuity → Replace. Switch position 8370

8-24

Home position

Depressed

Lead color Blue/Yellow (L/Y)

Black (B)

ELEC

–

STARTER MOTOR

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

6 19

7 8

9 A

6 × 52 mm

18 29

20 A

12 27 23 17

16 15

3 25

13 24 11

10 6 × 120 mm

Order

1 2 3 4 5 6 7 8 9

1 A

4 × 14 mm

Job/Part Starter motor Nut Bolt Relay (magnetic switch) Rubber dust Spring Starter motor pinion clip Starter motor pinion stopper Starter motor pinion Spring

Q’ty

8380

Remarks Refer to “IGNITION COILS AND STARTER MOTOR” on page 5-14.

1 2 1 1 1 1 1 1 1 Continued on next page.

8-25

ELEC

–

STARTER MOTOR

E 8

6 19

7 8

9 A

6 × 52 mm

18 29

20 A

12 27 23 17

16 15

3 25

13 24 11

10 6 × 120 mm

Order 10 11 12 13 14 15 16 17 18 19

1 A

4 × 14 mm

Job/Part Bolt Screw Yoke assembly Rear cover Thrust washer Plate Brush holder assembly Brush assembly Armature Center bracket plate

Q’ty 2 2 1 1 1 1 1 1 1 1

8380

Remarks

Continued on next page.

8-26

ELEC

–

STARTER MOTOR

E 8

6 19

7 8

9 A

6 × 52 mm

18 29

20 A

12 27 23 17

16 15

3 25

13 24 11

4 × 14 mm

6 × 120 mm

Order 20 21 22 23 24 25 26 27 28 29

Job/Part Shift lever Outer ring gear Planetary gear E-ring Pinion shaft Center bracket Thrust washer Clutch assembly Bearing Housing

Q’ty 1 1 3 1 1 1 1 1 1 1

8380

Remarks

For assembly, reverse the disassembly procedure.

8-27

ELEC

–

STARTER MOTOR

REMOVING THE STARTER MOTOR PINION

Remove: • Clips 1 NOTE: Slide the pinion gear down as shown and then remove the clips 1 with a thin screw driver.

8390

CHECKING THE STARTER MOTOR PINION

1. Check: • Starter motor pinion teeth Damage/wear → Replace. 2. Check: • Starter motor pinion movement Incorrect → Replace.

8400

NOTE: Rotate the starter motor pinion counterclockwise and make sure it moves smoothly. Also, rotate the starter motor pinion clockwise and make sure it locks.

8410

CHECKING THE ARMATURE 1. Check: • Commutator Foreign matter → Clean. (with 600 grit sandpaper)

8420

2. Measure: • Commutator diameter Out of specification → Replace. Commutator diameter limit 28.0 mm (1.10 in)

8430

8-28

ELEC

–

STARTER MOTOR

E 3. Check: • Commutator undercut Dirt/foreign matter → Clean. (with compressed air)

8440

4. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.2 mm (0.01 in) 8450

5. Check: • Armature continuity Out of specification → Replace. Armature continuity

8460

Commutator segments a

Continuity

Segment – Armature core b

No continuity

Segment – Armature shaft c

No continuity

MEASURING THE BRUSHES

1. Measure: • Brush length Out of specification → Replace the brush assembly. Brush length limit a 9.5 mm (0.37 in) 8470

8-29

ELEC

–

STARTER MOTOR

E 2. Check: • Brush assembly continuity Out of specification → Replace the brush assembly.

Brush assembly continuity Brush 1 – Brush 2

No continuity

8480

CHECKING THE MAGNETIC SWITCH RELAY

Check: • Magnetic switch relay continuity Out of specification → Replace. Checking steps (1) Remove the terminal 1 from the magnetic switch relay. NOTE: Remove the terminal to prevent the pinion gear from turning. (2) Connect the tester leads between the magnetic switch relay terminals as shown. (3) Connect the Brown/white (Br/W) lead to the positive battery terminal. (4) Connect the starter motor body to the negative battery terminal.

8481

CAUTION: Do not connect the battery for more than one second. Otherwise, the magnetic switch relay may be damaged. (5) Check that there is continuity between the magnetic switch relay terminals. (6) Check that there is no continuity after the Br/W lead is removed. NOTE: The starter motor pinion should be pushed out while the magnetic switch is on. (7) Install the terminal to the magnetic switch relay.

8-30

ELEC

â&#x20AC;&#x201C;

CHARGING SYSTEM

G G

1 G R

3 R

8490

1 2 3 4

Stator coil Rectifier/regulator Fuse (30A) Battery

B G R

8-31

: Black : Green : Red

ELEC

–

CHARGING SYSTEM

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page 8-11.

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE

Measure: • Lighting coil output peak voltage Measure with the rectifier/regulator output wire (red) disconnected. Below specification → Replace the lighting coil.

Lighting coil output peak voltage Green (G) – Green (G)

r/min V

Unloaded Loaded

Cranking 9.3

Unloaded 1,500

3,500

7.4

Test harness (6-pin) 90890-06790 8200

MEASURING THE RECTIFIER/ REGULATOR OUTPUT PEAK VOLTAGE

Measure: • Rectifier/regulator output peak voltage Below specification → Replace the rectifier/regulator.

Rectifier/regulator output peak voltage Red (R) – Black (B) G

r/min V

Loaded

Unloaded

Cranking —

7.5

1,500

3,500

12.5

13.0

Test harness (6-pin) 90890-06790 8200

8-32

ELEC

–

POWER TRIM AND TILT SYSTEM

2 Sb R Lg Up Free Down Lg

B Sb

Lg Lg Lg

Sb R

3 Lg Sb

Lg B

R B Sb B

P R B

P B

B P B

8500

1 2 3 4 5 6

Power trim and tilt motor Trailer switch 10P connector Trim sensor Battery Power trim and tilt relay

B Lg P R Sb

Å To remote control ı To trim meter 8-33

: Black : Light green : Pink : Red : Sky blue

ELEC

–

POWER TRIM AND TILT SYSTEM

CHECKING THE BATTERY

Refer to “CHECKING THE BATTERY” on page 3-21.

CHECKING THE POWER TRIM AND TILT RELAY

1. Check: • Power trim and tilt relay continuity Out of specification → Replace.

1 + Lg

Power trim and tilt relay continuity

2 8510

Sky blue (Sb) – Black (B) Continuity Light green (Lg) – Black (B)

Terminal 1 – Terminal Terminal 2 – Terminal -

Continuity

Terminal 1 – Terminal + Terminal 2 – Terminal +

No continuity

2. Check: • Power trim and tilt relay operation No continuity → Replace.

8520

Checking steps (1) Connect the digital tester between power trim and tilt relay terminals 1 and +. (2) Connect a 12-V battery as shown.

Light green (Lg) lead → Positive terminal Terminal - → Negative terminal

1+ Lg

(3) Check that there is continuity between the power trim and tilt relay terminals. (4) Connect the digital tester between power trim and tilt relay terminals + and 2. (5) Connect a 12-V battery as shown.

8530

Sky blue (Sb) lead → Positive terminal Terminal - → Negative terminal +2

(6) Check that there is continuity between the power trim and tilt relay terminals.

Sb 8540

8-34

ELEC

–

POWER TRIM AND TILT SYSTEM

CHECKING THE TRAILER SWITCH CONTINUITY

Check: • Trailer switch continuity Out of specification → Replace. Lead color Switch Light position Sky blue Red (R) green (Sb) (Lg)

8550

Up Free Down

MEASURING THE TRIM SENSOR RESISTANCE

Measure: • Trim sensor resistance Out of specification → Replace. Trim sensor resistance Pink (P) – Black (B) 238.8 - 378.8 Ω at 20 ˚C (68 ˚F) a 9 - 11 Ω at 20 ˚C (68 ˚F) b

8560

NOTE: Turn the lever 1 and measure the resistance as it gradually changes.

8-35

ELEC

–

POWER TRIM AND TILT MOTOR

DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR

8570

Order

1 2 3 4 5 6 7

Job/Part Power trim and tilt motor Screw Lead holder Screw Stator Armature O-ring Screw

Q’ty

Remarks Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-33.

1 1 2 1 1 1 2 Continued on next page.

8-36

ELEC

–

POWER TRIM AND TILT MOTOR

E 8

8570

Order 8 9 10 11 12 13

Job/Part Brush holder Brush Spring Lower cover Oil seal Bearing

Q’ty 2 2 2 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

8-37

ELEC

–

POWER TRIM AND TILT MOTOR REMOVING THE STATOR

E 8

Remove: • Stator 1

CAUTION: • Keep the power trim and tilt motor leads inside the stator. • Do not allow grease or oil to contact the commutator.

8580

NOTE: • Remove the lead holder 2 and rubber spacer 3 from the stator and slide them towards the leads. • Hold the end of the armature shaft with a clean cloth and pull off the stator.

REMOVING THE BRUSH

1. Remove: • Sky blue power trim and tilt motor lead 1 NOTE: Hold the brush with a screwdriver as shown. Then, disconnect the sky blue lead. 8590

2. Remove: • Brush holders 1 • Brushes 2

CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 8600

CHECKING THE BRUSH 1. Measure: • Brush length a Out of specification → Replace. Brush length 4.8 mm (0.19 in) 8610

8-38

ELEC

–

POWER TRIM AND TILT MOTOR

2. Check: • Brush continuity No continuity → Replace.

CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 8620

CHECKING THE ARMATURE

1. Measure: • Commutator diameter a Out of specification → Replace. Commutator diameter limit 21.0 mm (0.83 in) 8630

2. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.85 mm (0.03 in) 8640

3. Check: • Armature continuity Out of specification → Replace. Armature continuity

8650

8660

8-39

Commutator segments

Continuity

Segment-laminations

No continuity

Segment-shaft

No continuity

ELEC

–

POWER TRIM AND TILT MOTOR INSTALLING THE BRUSH

E 8

Install: • Brushes 1 • Brush holders 2 • Power trim and tilt motor leads 3 • Screw 4

CAUTION: 8670

Do not touch the bimetal; touching it may affect the operation of the breaker.

INSTALLING THE ARMATURE

Install: • Armature 1 NOTE: Push the brushes into the holder and then install the armature. 8680

INSTALLING THE STATOR

Install: • Stator 1 NOTE: Place a clean cloth over the end of the armature shaft and carefully push the armature into the stator with a pair of pliers as shown.

8690

8-40

TRBL ANLS

CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................................................................................... 9-1 TROUBLE ANALYSIS CHART ................................................................. 9-1 SELF-DIAGNOSIS ........................................................................................... 9-5 DIAGNOSIS CODE INDICATION ............................................................. 9-5 DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM ............................ 9-5 TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION............................ 9-7

1 2 3 4 5 6 7 8 9

TRBL ANLS

TROUBLE ANALYSIS

NOTE: The following items should be checked before the “TROUBLE ANALYSIS CHART” is consulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3. Wiring connections are properly secured and are not rusty. 4. The engine stop lanyard is installed onto the engine stop lanyard switch. 5. The shift position is in neutral. 6. Fuel is reaching the vapor separator. 7. The rigging and engine setting are correct. 8. The engine is free from any “Hull problem”.

TROUBLE ANALYSIS CHART

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

Check elements

LOOSE STEERING

LOW OIL PRESSURE

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

FUEL SYSTEM Low-pressure fuel line • Fuel line • Fuel filter • Fuel pump High-pressure fuel line • Vapor separator • High-pressure fuel pump • High-pressure fuel line • Fuel injectors Link adjustment

9-1

Reference chapter

3 3 4 4 4 3 4 3

TRBL ANLS

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

Check elements

LOOSE STEERING

LOW OIL PRESSURE

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

POWER UNIT Compression Cylinder head gaskets Cylinder block Crankcase Piston rings Pistons Bearings Thermostat Water passages Valve(s) and valve seat(s) Valve clearance adjusting shim(s) Camshaft(s) Timing belt Oil pump â&#x20AC;¢ Engine oil Oil filter Oil pressure switch LOWER UNIT Neutral position Dog clutch Gears Water inlets Water pump Propeller shaft(s) Shift rod joint/pin Shift cam Shift shaft Lower case

9-2

Reference chapter

3 5 5 5 5 5 5 5 5 5 5 5 5 6 3 3 8 6 6 6 6 6 6 6 6 6 6

TRBL ANLS

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

Check elements

LOOSE STEERING

LOW OIL PRESSURE

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

Reference chapter

BRACKET UNIT Bracket Rubber mount Shift rod POWER TRIM AND TILT UNIT Fluid level Relief valve Fluid passages Power trim and tilt motor ELECTRICAL Ignition system • Pulser coils • ECM • Ignition coils • Spark plugs Ignition/fuel control system • Engine stop lanyard switch • Main relay • High-pressure fuel pump resistor • Intake aie pressure sensor • Intake air temperature sensor • Engine cooling water temperature sensor • Throttle position sensor • Idle speed control assembly

9-3

7 7 7 3 7 — 7

8 8 8 3 — 8 8 8 8 8 8 4

TRBL ANLS

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

LOOSE TILT HOLDING

Check elements

LOOSE STEERING

LOW OIL PRESSURE

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

Starting system • Engine start switch • Shift position switch • Starter relay • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads • Battery Power trim and tilt system • Trailer switch • Power trim and tilt relay

9-4

Reference chapter

— 8 8 8 8 8 8 — — 8 8

TRBL ANLS

SELF-DIAGNOSIS

SELF-DIAGNOSIS DIAGNOSIS CODE INDICATION

1. Normal condition (no defective part or irregular processing is found) Single flash is given every 4.95 seconds. a : Light on, 0.33 second b : Light off, 4.95 seconds 9010

2. Trouble code indication Example: The illustration indicates code number 23. a b c d

: Light on, 0.33 second : Light off, 0.33 second : Light off, 1.65 seconds : Light off, 4.95 seconds

9020

DIAGNOSIS THE ELECTRONIC CONTROL SYSTEM

1. Install: • Diagnostic indicator Diagnostic test lead YB-06795 9030

NOTE: When performing this diagnosis, all of the electrical wires must be properly connected.

2. Check: • Diagnosis code Code 1 is indicated → Normal. Code 13 - 29 indicated → Check the applicable parts. Code 37 - 59 indicated → Microcomputer processing information.

9-5

TRBL ANLS

SELF-DIAGNOSIS

E Checking steps (1) Remove the diagnosis connector (3pins) cap. (2) Connect the special tools to the outboard motor as shown. (3) Start the engine and let it idle. (4) Check the diagnostic indicatorâ&#x20AC;&#x2122;s flash pattern to determine if there are any malfunctions. NOTE: When more than one problem is detected, the diagnostic testerâ&#x20AC;&#x2122;s light flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected.

9040

Diagnosis code chart Code

9-6

Symptoms

Normal

Incorrect pick-up coil input signal

Incorrect engine cooling water temperature sensor input signal

Incorrect throttle position sensor input signal

Incorrect battery positive voltage

Incorrect intake air temperature sensor input signal

Incorrect shift position switch

Incorrect intake air pressure sensor input signal (out of normal operating range)

37 - 59

Microcomputer processing information

(37)

Intake passage air leakage

(44)

Engine stop lanyard switch control operating

(49)

Ignition timing is being slightly corrected (when starting a cold engine)

(59)

Memory data over written abnormally

TRBL ANLS

TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION

TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION Items 1. Poor starting/ Engine will not start

Symptoms 1. No firing. The starter motor cranks the engine, but no firing is generated in the cylinder. 2. The firing is generated in the cylinder, but the engine soon stops. 3. Start-up time is too long. The engine will not start-up easily. 1. Check the high-pressure fuel lines. 1) Check for fuel line leaks 2) Check the fuel pressure

Fuel pressure is out of specification

1 Check the 20-A fuse 2 Check the main relay

3) Check the operation of the fuel injector

3 Check the high-pressure fuel pump operation

4) Check the diagnosis cord

4 Check the main relay driveâ&#x20AC;&#x2122;s ECM output 5 Check the pressure regulator

2. Check the ignition system. 1) Check the wire harness 2) Check the ignition spark 3) Check the ignition coil 4) Check the ECM output peak voltage 5) Check the pulser coil output peak voltage

9-7

TRBL ANLS

TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION

Items 2. Erratic idling speed

Symptoms 1. The engine speed is not constant when idling. 2. The engine stalls when the throttle lever is pulled back. 3. The engine stalls when the throttle lever is opened or during outboard operation. 1. Check the high-pressure fuel lines. 1) Check for fuel line leaks 2) Check the fuel pressure

Fuel pressure is out of specification

1 Check the 20-A fuse 2 Check the main relay

3) Check the operation of the fuel injector

3 Check the high-pressure fuel pump operation

4) Check the diagnosis cord

4 Check the pressure regulator

2. Check the ignition system. 1) Check the wire harness 2) Check the ignition spark 3) Check the ignition coil 4) Check the ECM output peak voltage 5) Check the pulser coil output peak voltage

3. Check the ignition timing. 1) Check the diagnosis cords

1 Check the pulser coil diagnosis cord 2 Check the engine cooling water temperature sensor diagnosis cord 3 Check the intake air temperature sensor diagnosis cord

9-8

TRBL ANLS

TROUBLE SHOOTING FOR ELECTRIC FUEL INJECTION

Items 3. Erratic engine speed

Symptoms 1. The engine is started, but will not run smoothly. The engine speed drops during acceleration. 1. Check the high-pressure fuel lines. 1) Check for fuel line leaks 2) Check the fuel pressure

Fuel pressure is out of specification

1 Check the 20-A fuse 2 Check the main relay

3) Check the operation of the fuel injector

3 Check the high-pressure fuel pump operation

4) Check the diagnosis cord

4 Check the main relay driveâ&#x20AC;&#x2122;s ECM output 5 Check the pressure regulator

2. Check the ignition system. 1) Check the wire harness 2) Check the ignition spark 3) Check the ignition coil 4) Check the ECM output peak voltage 5) Check the pulser coil output peak voltage

3. Check the ignition timing. 1) Check the diagnosis cords

1 Check the pulser coil diagnosis cord 2 Check the engine cooling water temperature sensor diagnosis cord 3 Check the intake air temperature sensor diagnosis cord

9-9

WIRING DIAGRAM

F115TR, LF115TR L Oil pressure switch P/W

1 Engine cooling temperature sensor

2 Power trim and tilt motor

N M S P/W Lg

B/Y

B/Y B

B/Y B B/W R/Y B/R

B/W B/R

R/Y

G Pulser coil 1

B P

B/R B

B/R B/R

#4 R/Y

R/Y

5 Trim sensor

R/Y B/W P

B B P/B P/W G B W P R Y Sb Br Lg

R/Y

4 Ignition coil B/W #2 B/W B/W

#3 R/Y

R/Y

Å Tiller handle model

B/W B/Y

Sb G/W

W B R Y Br R Y

P O

P/B

R/Y B

Lg Sb

B W/R W/B

W/B

W/R

L/Y

P/W

T Injector #1 R/Y

B/Y R/Y

Pu/R

B/Y Pu/R

M Air temperature sensor

Pu/R

B B Pu/G Pu/Y B R/Y

U Injector #2 R/Y

W/B

W B/Y

P/B

L/W

B/W

N ISC

B B B B B B B

P R/Y Br/W

• • S4 I2 S2 S3 I2 S1

Pu/B

P/W

R/Y

Pu/B L Pu/B

G B/R

G/Y B

G/R

G/R R/Y

P/G

G/B

Br B G/R G/W Sb Lg G P R B P/B O W O/W L

J ECM

R G

G/B W/R

W/B

P/G B O

R/Y

B/Y

P/W

P/B

G/R R/Y G/Y G/B R/Y G

G/Y

G/R

C Starter relay G/W

B Lg

P/G

G/W

S Intake air pressure sensor

R/Y

P P/B P/B G/R

I Pulser coil 2

W/R

W/B

B B B B B B

G/R

R/Y R/Y R/Y R/Y R/Y R/Y R/YR/Y

P/B

FREE START

W/B B W/R

6 Engine 7 Main switch W B R Y Br stop switch UP

Sb Lg R

B P O

G G

P/B

B Power trim and tilt relay

3 Spark plug #1

R Throttle position sensor

H Lighting coil

8 Starter motor

V Injector #3

B B

R/Y B

R/Y

Pu/Y

D Diagnosis connector

Pu/Y

K Rectifier/regulator N M S

RR R

Br/W

O Fuel pump

E Main relay

W Injector #4 R/Y

W/B

R/B

R/Y

Pu/G

W/B R/B

Pu/G

B B

B Br

R/Y

R R R R

R/B W/B B Br

9 Battery

R R/Y B R/Y G

R R R

Å Tiller handle model 0 Power trim and tilt switch

Sb R Lg

Sb R Lg UP FREE DOWN

L/Y

Q Fuse 3 20A

B L/Y

L/W

Q Fuse 4 20A

: Black

B/R : :Black/red

Pu/B : Purple/black

: Brown

B/W : Black/white

Pu/G : Purple/green

: Green

B/Y : Black/yellow

Pu/R : Purple/red

: Blue

Br/W : Brown/white

Pu/Y : Purple/yellow

: Light green

G/R : Green/red

R/B : Red/black

: Orange

G/W : Green/white

R/Y : Red/yellow

: Pink

G/Y : Green/yellow

W/B : White/black

: Purple

G/B : Green/black

W/R : White/red

: Red

L/W : Blue/white

: Sky blue

L/Y

: White

P/B : Pink/black

: Yellow

P/G : Pink/green

B/O : Black/orange

P/W : Pink/white

Sb R Lg

COLOR CODE R

A Trailer switch

Lg Sb R

Sb R Lg Lg

R R R

Sb R Lg UP FREE DOWN

Lg Sb R

X Shift position switch P Fuse 2 30A

L/Y

Y B R/Y G R R R/Y L/W Lg Sb

P Fuse 1 30A

F Diagnosis lamp connector

: Blue/yellow

YAMAHA MOTOR CORPORATION, USA

Printed in USA Oct. 2003 – 0.0 × 1 CR (E)